06 Engine | Distributor | Piston

L-6 Engine

6A-1

ENGINE
33 THROUGH 86 SERIES
REFER TO PAGE 6K-1 FOR AIR INJECTION REACTOR SYSTEM ( K - 1 9 A N D K - 2 0 ) REFER TO PAGE. . 6L-1 FOR CARBURETION REFER TO PAGE. . . 6 M - 1 FOR V - 8 ENGINE REFER TO PAGE 6B-1 FOR T U N E - U P - L - 6 A N D V - 8 REFER TO PAGE 6C-1 FOR ENGINE C O O L I N G - L - 6 A N D V - 8 -

CONTENTS OF SECTION 6A—L-6 ENGINE

Subject

Page

Subject

Page 6A-16 6A-16 6A-16 6 A-17 6A-17 6A-18 6A-18 6A-18 6A-19 6A-20 6A-20 6A-20 6A-22 6A-22 6A-25 6A-26 6A-26 6A-26 6A-27 6A-28 6A-30 6A-30 6A-30 6A-31 6A-31 6A-31 6A-32 6A-32 6A-33 6A-33 6A-33 6A-34 6A-34 6A-35 6A-36

DESCRIPTION ENGINE ASSEMBLY REMOVAL INSTALLATION . MANIFOLD ASSEMBLY REMOVAL INSTALLATION ROCKER ARM COVER REMOVAL INSTALLATION ROCKER ARM ASSEMBLY REMOVAL INSTALLATION AND ADJUSTMENT . ROCKER ARM STUDS REMOVAL AND INSTALLATION . . . VALVE LIFTERS LOCATING NOISY LIFTERS REMOVAL INSTALLATION DISASSEMBLY CLEANING AND INSPECTION . . . . ASSEMBLY VALVE STEM OIL SEAL AND/OR VALVE SPRING REPLACEMENT (ON CAR) CYLINDER HEAD ASSEMBLY REMOVAL INSTALLATION DISASSEMBLY . CLEANING INSPECTION VALVE GUIDE BORES VALVE SEATS VALVES OIL PAN REMOVAL INSTALLATION OIL PUMP REMOVAL DISASSEMBLY CLEANING AND INSPECTION . . . . ASSEMBLY INSTALLATION REAR MAIN OIL SEAL REPLACEMENT TORSIONAL DAMPER

6A-2 6A-2 6A-2 6A-4 6A-4 6A-5 6A-5 6 A _5 6A-5 6 A _6 6 A _6 6A-6 6A_7 6A_7 6A_7 6A_8 6A_8
6A_9 6A_9

6A-10 6A-10 6A-10 6A-10 6A-10 6A-11 6A-12 6A-12 6A-13 6A-13 6A-13 6A-14 6A-14 6A-14 6A-14 6A-15 6A-15

REMOVAL INSTALLATION CRANKCASE FRONT COVER REMOVAL INSTALLATION OIL SEAL (FRONT COVER) REPLACEMENT CAMSHAFT MEASURING LOBE LIFT REMOVAL INSPECTION OIL NOZZLE REPLACEMENT . . . . CAMSHAFT GEAR REPLACEMENT . INSTALLATION CAMSHAFT BEARING REPLACEMENT TIMING GEAR REPLACEMENT. . . . MAIN BEARINGS CONNECTING ROD BEARINGS CONNECTING ROD AND PISTON REMOVAL DISASSEMBLY . PISTON PINS PISTON RINGS CRANKSHAFT REMOVAL CLEANING AND INSPECTION . . . . INSTALLATION CYLINDER BLOCK CLEANING AND INSPECTION . . . . OIL FILTER BY-PASS VALVE . . . . DISTRIBUTOR BEARING REPAIRS CYLINDER CONDITIONING CYLINDER BORING PISTON SELECTION FLYWHEEL REMOVAL INSTALLATION ENGINE MOUNTS ENGINE TORQUES SPECIFICATIONS FUEL PUMP - Refer to V-8 Engine . . TOOLS

6A-2

L-6 Engine

6. Disconnect wires at: • • • • • Starter Solenoid Delcotron Temperature Switch Oil Pressure Switch Coil

7. Disconnect: • • • • Accelerator linkage at manifold bellcrank. Exhaust pipe at manifold flange. Fuel line (from tank) at fuel pump. Vacuum line to power brake unit at manifold (if so equipped). • Power steering pump lines at pump end (if so equipped).

8. Raise vehicle and place on jack stands. 9. Remove propeller shaft.
Fig. 6A-1 DESCRIPTION L-6 Engine

NOTE: If plug for' propeller shaft opening in transmission is not available, drain transmission. 10. Disconnect:

The in-line L-6 250 cu. in. engine is standard in the 33 and 35 Series. (Fig. 6A-1) The L-6 engine cylinders are numbered from front to r e a r with the firing order 1-5-3-6-2-4. Crankshaft rotation as viewed from the rear is counterclockwise. The crankshaft has seven main bearings and the camshaft is supported by four bearings. Full pressure lubrication, through a full flow oil filter is furnished by a gear-type oil pump. The distributor, driven by a helical gear on the camshaft, drives the oil pump. The main oil gallery feeds oil, through drilled passages to the camshaft and crankshaft to lubricate the bearings. The main oil gallery, also feeds the valve lifters which, through hollow push rods, feed the individually mounted rocker arms. (Fig. 6A-2)

• Shift linkage at transmission. • Speedometer cable at transmission. 11. On manual transmission equipped vehicles, disconnect clutch linkage at cross shaft, then remove cross shaft engine bracket. 12. Remove transmission assembly. 13. Remove front mount through bolts. 14. Attach BT-6606 and raise engine to take weight off front mounts, then remove rear mount bolts. (Fig. 6A-3) 15. Remove engine assembly from vehicle as a unit. 16. Mount engine in stand.

ENGINE ASSEMBLY
Installation Removal

1. Drain cooling system and engine oil. 2. Remove air cleaner and disconnect battery cables at battery. 3. Remove hood. 4. Remove radiator shroud. 5. Remove fan blade and pulley.

1. Attach BT-6606 to engine and remove engine from engine stand. 2. Tilt and lower engine assembly into the chassis, guiding engine to align front mounts with frame supports. 3. Install front mount through bolts and torque to specifications. 4. Raise engine enough to install rear cross-

L-6 Engine

6A-3

OIL PRESSURE SENDING UNIT

Fig. 6A-2

Engine Lubrication

4. 8. fan blade and fan belt. Fill with coolant. Connect exhaust pipe to manifold using a new packing. Disconnect carburetor. Center bolt and end bolt torque 11. Install transmission assembly. then start engine and check for leaks. MANIFOLD ASSEMBLY Removal 1. Position new gasket over manifold end studs on head and carefully install the manifold in position making sure the gaskets are in place. 10. • Fuel line at fuel pump. 6. Connect: • Power steering pump lines (if disconnected). install rear mount. • Shift linkage at transmission. Connect: • Speedometer cable. 12. lower engine and torque bolts to specifications. Torque bolts to specifications. 3. NOTE: differ. 2. Perform necessary adjustments and install air cleaner. Disconnect exhaust pipe at manifold flange and discard packing. 9. it will be necessary to replace the manifold. 5. Tighten finger tight and torque to specifications after assembly to cylinder head. Disconnect both throttle rods at bellcrank and remove throttle return spring. Remove manifold attaching bolts and clamps. separate them by removing one bolt and two nuts at center of assembly. Install pulley. Remove air cleaner. 13. 9. If necessary to replace either intake or exhaust manifolds. Install radiator and shroud. Check for cracks in manifold castings. then install crossmember. Connect battery cables. • Vacuum line to power brake unit (if disconnected). . then remove manifold assembly and discard gaskets. fuel and vacuum lines at 4. Remove jack stands and lower vehicle. • Accelerator linkage at manifold bellcrank. Connect wires at: • • • • • Coil Oil pressure switch Temperature switch Delcotron Starter solenoid 5. Check operation of heat r i s e r valve. 8. 2. engine oil and transmission oil. 3. Install propeller shaft. 16. Transfer all necessary parts. • Exhaust pipe at manifold flange. 7. Installation 1. Clean gasket surfaces on cylinder head and manifolds.6A-4 L-6 Engine 15. Install bolts and clamps while holding manifold in place with hand. Reassemble manifolds using a new gasket. 6A-3 Lifting Engine member. if unable to free up. 14. Disconnect crankcase ventilation hose at rocker arm cover. 7. Fig. 6. 5. Install and adjust hood.

then turn in adjusting nut until all lash is removed. Disconnect crankcase ventilation hose(s) at rocker arm cover. rocker arm balls and rocker arm nuts. turn adjusting nut in one full additional turn (to center lifter plunger). d. then disconnect plug wires at spark plugs and coil and remove distributor cap and plug wire assembly (if not previously done). 4. Remove rocker arm cover. with chalk. (Fig. Clean rocker a new torque gasket surfaces on cylinder head and arm cover with degreaser. . Installation 1. install rocker arm cover and bolts to specifications. 9 Install air cleaner. g Connect throttle rods at bellcrank and install throttle return spring. Gaskets adhering to cylinder head and rocker arm cover may be sheared by bumping end of rocker arm cover rearward with palm of hand or a rubber mallet. Be sure push rods seat in lifter socket. rocker Fig. 3. 2.L-6 Engine 6A-5 A Connect crankcase ventilation hose at rocker arm cover. b. 1. 3. check for leaks and adjust carburetor idle speed and mixture. Install push rods. 2. Disconnect temperature wire from arm cover clips. 2. then using gasket. rocker arm balls and push rods in a rack so they may be reinstalled in the same location. Back out adjusting nut until lash is felt at the push rod. Adjust valves when lifter is on base circle of camshaft lobe as follows: a. Mark distributor housing. at each cylinder position (plug wire). Crank engine until distributor rotor points to number one cylinder position and breaker points are open. 3. Remove rocker arm nuts. 6A-4) When play has been removed. NOTE: Do not pry rocker arm cover loose. Install air cleaner. start engine. NOTE: Place rocker arms. 7 Connect fuel and vacuum lines at carburetor. Tighten rocker arm nuts until all lash is eliminated. Connect crankcase ventilation hoses. 6A-4 Valve Adjustment Installation and Adjustment NOTE: Whenever new rocker arms and/or rocker a r m balls are being installed. wire at rocker arm 2. ROCKER ARM COVER Removal 1. Remove air cleaner. one cylinder at a time. Install rocker arms. rocker arm balls. This can be determined by checking push rod side play while turning adjusting nut. coat bearing surfaces of rocker arms and rocker arm balls with Molykote or its equivalent. c. ROCKER A R M ASSEMBLY Removal 1. in the same manner. rocker arms and push rods. Connect temperature cover clips. Remove rocker arm cover as outlined. Adjust the remaining valves. Both valves on number one cylinder may now be adjusted. 4.

6 I n s t a l l i n g Rocker Arm Stud 3. 6 A . Install distributor cap and spark plug wire assembly.5 Reaming Rocker A r m Stud Hole 4. 6 A . 4. stud as shown in Fig. Install rocker arm cover as outlined. 6. idle speed and mixture.6A-6 L-6 Engine Fig. Install new stud as shown in Fig.8 Removing Rocker Arm Stud VALVE LIFTERS Hydraulic valve lifters very seldom require attention. 2. If rocker arm stud is loose or pulled out of head refer to Fig. 6 A . tool should bottom on head. Place one end of the hose near the end of each . If rocker arm stud is stripped refer to Fig. Adjust carburetor ROCKER ARM STUDS 1.S. 5. 6A-5 and ream stud hole to next largest size. 6A-6. 6 A . NOTE: Oversize studs have the size marked on the bottom. Locating Noisy Lifters Fig. Locate a noisy valve lifter by using a piece of garden hose approximately four feet in length. 6A-8 for pulling the stud. 6A-6. Fig. Install new O. tool should bottom on head. and servicing of the lifters requires only that care and cleanliness be exercised in the handling of parts. readjustments are not necessary. The lifters are extremely simple in design. 6A-7 for rethreading and Fig.7 Removing Stripped Rocker Arm Stud Fig.

disassembled. coat foot of valve lifters with Molykote or its equivalent. a distinct shock will be felt when the valve returns to its seat. with chalk. then connect primary lead at coil. is shown to exist in one unit. b. be a definite indication of insufficient oil supply. reassembled. Install push rod covers. 6A-9) Disassembly 1. varnish. 3. (Fig. c. Moderate Rapping Noise . Improper adjustment. at each . Both lifters are easily identified by the outside configuration of the lifter body. 3. The complete lifter assemblies are interchangeable but parts from one lifter are not interchangeable with another. 2. remove the push rod seat retainer. The general types of valve lifter noise are as follows: 1. Remove push rod covers (discard gaskets). Removal 1. adjust valve mechanism as 5. Hard Rapping Noise--Usually caused by the plunger becoming tight in the bore of the lifter body to such an extent that the return spring can no longer push the plunger back up to working position. Remove the push rod seat and metering valve (lifter "A") or the push rod seat and inertia valve assembly (lifter " B " ) . NOTE: Place valve lifters in a rack so they may be reinstalled in the same location. c. usually caused by an abrasive piece of dirt or metal wedging between plunger and lifter body. b. Another method is to place a finger on the face of the valve spring retainer. 2. For purposes of identification we refer to them as lifter " A " and lifter " B " . positioning rotor to number one cylinder position. In r a r e cases. (Fig.This will. Install valve lifters. 5. and reinstalled in the engine. Intermittent Clicking--Probable causes are: cylinder position (plug wire). Mark distributor housing. etc. then disconnect distributor primary lead at coil and remove distributor.. Adjust ignition timing and carburetor idle speed and mixture. Improper adjustment. using new gaskets.. In most cases where noise exists in one or more lifters all lifter units should be removed. In this manner. Hold the plunger down with a push rod. 6A-10) 3. NOTE: Whenever new valve lifters are being installed. 4. Probable causes are: a. ball check valve assembly and the plunger spring. it niore than likely exists in all the units. If dirt. Remove valve lifters. 4. Both types of lifters operate on the same principle and are serviced basically in the same manner. Remove valve mechanism as outlined. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. Excessively high leakdown rate. the ball itself may be outof-round or have a flat spot. b. and using the blade of a small screw driver. Excessive varnish or carbon deposit causing abnormal stickiness. thus it would only be a matter of time before all lifters caused trouble. Leaky check valve seat. then disconnect plug wires at spark plugs and coil and r e move distributor cap and plug wire assembly. 2. VALVE LIFTERS (HYDRAULIC) a. in almost all cases.m L-6 Engine 6A-7 •ntake and exhaust valve with the other end of the hose to the ear.Probable causes are: a. Install a n d outlined. Installation 1. Galling or "pickup" between plunger and bore of lifter body. 3. cleaned in a solvent. 2. If the lifter is not functioning properly. General Noise Throughout the Valve Train . and torque bolts to specifications. 4. or improper adjustment. the sound is localized making it easy to determine which lifter is at fault. carbon. Two types of hydraulic lifters are used. Crank engine until distributor rotor points to number one position. Remove the plunger. Install distributor.

refill assembly with SAE 10 oil. If any parts are damaged or worn. 2. Cleaning and Inspection 1 Lifter Body 2 Push Rod Seat 3 Metering Valve (Lifter A) Inertia Valve (Lifter B) 4 Check Ball Fig. 6A-11) 3. Insert a 1/16" drift pin through both oil holes to hold the plunger down against the lifter spring tension. and inspect them carefully. the entire lifter assembly should be replaced: If the lifter body wall is scuffed or worn. 6A-12) NOTE: Do not attempt to force or pump the plunger. inspect the cylinder block lifter bore. At this point oil holes in the lifter body and plunger assembly will be aligned. 6A-9) should not be removed from the push rod seat. Remove the 1/8" drift pin. Assembly 1. 6A-9 5 6 7 8 9 Check Ball Retainer Push Rod Seat Retainer Plunger Check Ball Spring Plunger Spring Valve Lifter Assemblies 4. 6A-12) NOTE: On lifter " B " (Fig. (Fig. Remove the ball check valve and spring by prying the ball retainer loose from the plunger with the blade of a small screw driver. 6A-10) Thoroughly clean all parts in cleaning solvent. . Place the check ball on small hole in bottom of the plunger. Place the plunger spring over the ball retainer and slide the lifter body over the spring and plunger. Insert check ball spring on seat in ball retainer and place retainer over ball so spring r e s t s on the ball. 4. if the bottom of the lifter is scuffed or worn inspect the camshaft lobe. (Fig. 5. To check the valve. 6. shake the push rod seat and inertia valve assembly and the valve should move. 6A-9) the drifter pin must not extend inside the plunger. Carefully press the retainer into position in plunger with the blade of a small screw driver. if the push rod seat is scuffed or worn inspect the push rod. (Fig. Fill the assembly with SAE 10 oil. then insert the end of a 1/8" drift pin into the plunger and press down solid.6A-8 L-6 Engine LIFTER " A " LIFTER "B' Fig. being careful to line up the oil feed holes in the lifter body and plunger. (Fig. 6A-10 Removing Ball Check Valve NOTE: Inertia valve and retainer (lifter "B") (Fig.

NOTE: Before installing any new lifters. valve shield and valve cap in place. The lifter is now completely assembled. NOTE: Grease may be used to hold the locks in place while releasing the compressor tool. (Fig. Compress the spring with Tool BT-6413 and install oil seal in the lower groove of the stem. 6A-12 Assembling Hydraulic Lifters 7. NOTE: A tool to apply air to the cylinders to hold the valve is available. Fig. Fig. Remove the valve stem oil seal. remove the valve locks. 2. BT-72-1-B. Install the push rod seat retainer. making sure the seal is flat and not twisted. rocker arm and push rod on the cylinder(s) to be serviced. Install the metering valve and push rod seat (lifter "A") or the push rod seat and inertia valve assembly (lifter " B " ) . 6A-13) 5. 6A-11 Installing Ball Check Valve 3. Apply compressed air to the spark plug hole to hold the valves in place. Using the tool the valves can be removed with the cylinder head installed. Install the valve locks and release the compressor tool. Remove rocker arm cover as outlined. To replace. valve shield and valve spring and damper. press down on the push rod seat and remove the 1/16" drift pin from the oil holes. filled with oil and ready for installation. 6A-9) 8. set the valve spring and damper. making sure the locks seat properly in the upper groove of the valve stem. Remove spark plug. valve cap. 6A-13 Removing Valve Spring V A L V E STEM O I L SEAL A N D / O R VALVE SPRING Replacement (On Car) 1. The close coiled end of the spring is installed against the cylinder head. NOTE: A light coat of oil on the seal will help prevent twisting. 7. 4. coat the bottom of the lifter with Molykote or its equivalent. 6. Using Tool BT-6413 to compress the valve spring. (Fig. .L-6 Engine 6A-9 Fig.

9. Coat threads of cylinder head bolts with sealing compound and install finger tight. 5. 7. Drain cooling system (block). 6A-14) and remove valve keys. remove valve rocker arm nuts. NOTE: The gasket surfaces on both the head and the block must be clean of any foreign matter and free of nicks or heavy scratches. Connect temperature sending unit wires and install fuel and vacuum lines in clip at water outlet. using a new gasket. Cylinder bolt threads in the block and threads on the cylinder head bolt must be cleaned. 9. then disconnect wires from temperature sending units. CYLINDER HEAD ASSEMBLY 7. and torque to specifications. 6. Disconnect upper radiator hose at water outlet housing and battery ground strap at cylinder head. 6A-16) 3. Using a valve spring compressing tool.6A-10 L-6 Engine bolt torque. (Dirt will affect . Remove fuel and vacuum line from retaining clip at water outlet. Carefully guide cylinder head into place over dowel pins and gasket. rocker arms and push rod guides. 6A-15) 2. Start engine and allow warm up. 11. Clean all carbon from combustion chambers and valve ports. 10. 6. ball and rocker arms (if not previously done). Install and adjust valve mechanism as outlined.) Do not use gasket sealer on composition steel asbestos gasket. Installation 1. 3. (Fig. 2. radiator hose and engine Fig. 4. Remove cylinder head bolts. compress the valve springs (Fig. Thoroughly clean the valve guides. spring shields. 3. NOTE: Do not install rocker arm cover. 6 A . Clean all carbon and sludge from push rods. 4. Fill cooling system. 1. cylinder head and gasket. Remove manifold assembly as outlined. Release the compressor tool and remove spring caps. Install spark plug. Install coil. Connect upper ground strap. Remove valves from cylinder head and place them in a rack in their proper sequence so they can be assembled in their original positions. Cleaning 1. 2. Place cylinder head on two blocks of wood to prevent damage. 5. Remove coil. Tighten head bolts a little at a time until the specified torque is reached. 3. Place the gasket in position over the dowel pins with the bead up. remove oil seals and valve spring shims. With cylinder head removed. then. 8. then retorque cylinder head and readjust valves. (Fig. Remove valve mechanism as outlined. 2. Install manifold assembly as outlined. Disassembly ' Removal 1.1 4 Compressing V a l v e Springs 8. Install and adjust valve mechanism as outlined. springs and spring damper.

Inspection Valves with oversize stems are available. move the stem of the valve from side to side. using light pressure to obtain a clearance reading. locating the indicator so that movement of the valve stem from side to side (crosswise to Fig. If clearance exceeds specifications. Insufficient clearance will result in noisy and sticky functioning of the valve and disturb engine smoothness. 6A-19) 1. the springs can be checked. NOTE: Excessive valve stem to bore clearance will cause excessive oil consumption and may cause valve breakage. 6A-18 Checking Valve Spring Tension . (Fig. 2. Clean valve stems and heads on a buffing wheel. use Tool Set J-5830. Measure valve stem clearance (Fig. If a spring tension tool is available. (Fig. 6A-18) See Specification chart. 6A-17) as follows: Clamp a dial indicator on one side of the cylinder head rocker arm cover gasket rail. With the valve head dropped about 1/16" off the valve seat. Clean carbon deposits from head gasket mating surface. cracked faces or damaged stems. if not within 10 lbs. 6A-17 Fig.L-6 Engine 6A-11 Fig. VALVE GUIDE BORES Fig. Inspect the cylinder head for cracks in the exhaust ports. Inspect the valves for burned heads. of the specified load (without damper) the spring should be replaced. 6A-16 Cleaning Valve Guide 4. 3. 6A-15 Cleaning Combustion Chamber Measuring Valve Stem Clearance the head) will cause a direct movement of the indicator stem. Inspect rocker arm studs for wear or damage. Clean and inspect valve springs. 5. it will be necessary to ream valve guides for oversize valves as outlined. To ream the valve guide bores for oversize valves. The indicator stem must contact the side of the valve stem just above the valve guide. combustion chambers or external cracks to the water chamber.

(Fig. 5. Refer to specifications and Fig. 6A-21) Fig. 3. 6A-20. insuring correct relation between the head and stem. 4. Remove expanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations. burning or . VALVES Valves that are pitted can be refaced to the proper angle. place finishing stone. Install expanding pilot in the valve guide bore. 1. however. over pilot and cut just enough metal from the seat to provide a smooth finish. When a valve head which is warped excessively is refaced. Knife edges lead to breakage. Remove roughing stone or forming stone from pilot. 6.6A-12 L-6 Engine INTERFERENCE Fig. Place roughing stone or forming stone over pilot and just clean up the valve seat. Narrow the valve seats to the specified width. 002" total indicator reading. Several different types of equipment are available for reseating valve seats. Good contact between each valve and its seat in the head is imperative to insure that the heat in the valve head will be properly carried away. on a valve refacing mechanism. Use a stone cut to specifications. 6A-20 Relation of Valve and Seat Angles NOTE: This operation is done by grinding the port side with a 30° stone to lower seat and a 60° stone to raise seat. cut to specifications. Measure valve concentricity. a knife edge will be ground on part or all of the valve head due to the amount of metal that must be removed to completely reface. 6A-21 Measuring Valve Seat Concentricity NOTE: Valve seats should be concentric to within . Another important factor is the cooling of the valve heads. Regardless of what type of equipment is used. Fig. because the seating of the valves must be perfect for the engine to deliver the power and performance built into it. 2. it is essential that valve guide bores be free from carbon or dirt to insure proper centering of pilot in the guide. 6A-19 V A L V E SEATS Reaming Valve Guide Bores Reconditioning the valve seats is very important. Valve stems which show excessive wear or valves that are warped excessively should be replaced. The recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results.

9. 2. 4. NOTE: Grease may be used to hold the locks in place while releasing the compressor tool. Operate the vacuum and make sure no air leaks past the seal. Assemble the valve spring and related parts as follows: a. 6A-26) . Clamp the valve stem in the chuck of the machine.) the valve must be replaced as the valve will overheat and burn. Grind and check the remaining valves in the same manner. Install the remaining valves. Do not grind end of stem excessively. To remove the engine oil pan. I If necessary. Insert a valve in the proper port. NOTE: Only the extreme end of the valve stem is hardened to resist wear. OIL PAN 1. it is necessary to remove the engine from the car. valve spring. Several different types of equipment are available for refacing valves. Start the grinder and move the valve head in line with the grinder wheel. 6A-22) The close coiled end of the spring is installed against the cylinder head. Feed valve squarely against grinding wheel to grind any pit from rocker arm end of stem. (Fig. Set the valve spring shim.L-6 Engine 6A-13 ignition due to heat localizing on this knife P. The oil pump is driven by the distributor shaft which is driven by the helical gear on the camshaft. After cleaning valve face and cylinder head valve seat of grinding particles. place the valve in cylinder head and give the valve 1/2 turn in each direction while exerting firm pressure on head of valve. it will be necessary to repeat the refacing operation and again recheck for proper seating. Refer to ENGINE. A cutaway scale will help. 6A-20. replace the valve. dress the valve refacing machine grinding wheel to make sure it is smooth and true. (Fig. make pencil marks about 1/4" apart across the valve face. Install the valve locks and release the compressor tool. 3. Fig. 2. If this makes the valve head thin (1/32" min. valve shield and valve cap in place. Install oil seal in lower groove of stem. Removal and Installation. 6A-25A illustrates gasket and seal installation. 5. (Fig. At no time should the spring be shimmed to give an installed height under the minimum specified. Be sure the seal is flat and not twisted. Check the installed height of the valve springs using a narrow thin scale. Refer to specifications and Fig. 6A-24) Measure from the top of the shim or the spring seat to the top of the valve spring shield. A vacuum cup can be made from a small syringe and a high voltage shield. valve damper. install a valve spring seat shim approximately 1/16" thick. If all pencil marks have not been removed at the point of contact with the valve seat. d. Turn the feed screw until the valve head just contacts wheel. 7. 6. Move valve back and forth across the wheel and regulate the feed screw to provide light valve contact. making sure the locks seat properly in the upper groove of the valve stem. e If t n e e < ^S e °f t n e v a l v e head is less than W32" thick after grinding. 3. Remove valve and check face carefully. 8. 4. 6A-25) If this is found to exceed the specified height. Continue grinding until the valve face is true and smooth all around the valve. Remove valve from chuck and place stem in " V " block. Assembly Fig. (Fig. OIL PUMP The oil pump consists of two gears and a pressure regulator valve enclosed in a two-piece housing. 6A-22 Valve Spring Installation c. Set check at angle specified for valve. Check each valve stem oil seal by placing a vacuum cup or similar device over the end of the valve stem and against the cap. The recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results. b. Compress the spring.

6A-16

L-6 Engine

Fig. 6A-30

Removing Torsional Damper

Fig. 6A-29

Removing O i l Seal (Upper Half)

4. To remove the upper half of the seal, use a small hammer to tap a brass pin punch on one end of seal until it protrudes far enough to be removed with pliers. (Fig. 6A-29) NOTE: Always clean crankshaft surface removing all foreign deposits before installing a new seal. Also clean seal grooves. 5. Lubricate the lip and OD of a new seal with engine oil. Keep oil off the parting line surface. Gradually push with a hammer handle, while turning crankshaft, until seal is rolled into place. (Similar to installing a main bearing. ) Be careful that seal bead on OD is not cut. Compress seal towards crankshaft as much as possible. 6. Install the rear main bearing cap (with new seal) and torque to specifications. Be sure cross seal tabs are in place and properly seated.
TORSIONAL DAMPER Removal

Fig. 6A-31

Installing Torsional Damper

3. Install tools as shown in Fig. 6A-30 and remove damper. Remove tools.
Installation

1. Coat front cover oil seal contact area of damper with engine oil. 2. Position damper on crankshaft and drive into position, using J-5154, until it bottoms against crankshaft gear. (Fig. 6A-31) 3. Install belts and adjust. 4. If so equipped, install accessory drive pulley and belt. 5. Install radiator, fill cooling system and check for leaks.
CRANKCASE FRONT COVER Removal

1. Remove oil pan as outlined. 2. Remove outlined. crankshaft torsional damper as

1. Remove radiator core. 2. Remove fan belt and (if so equipped) accessory drive pulley and belt.

L-6 Engine

6A-17

Fig. 6A-33

Installing Oil Seal (Cover Removed)

NOTE:
Fig. 6A-32 Installing Front Cover

Support cover at sealing area.

3. Remove crankcase front cover attaching bolts, cover and gasket.
Installation

Without Cover Removal

1. Clean gasket surfaces on block and crankcase front cover. 2. Install centering Tool J-21742 in crankcase front cover seal. (Fig. 6A-32) 3. Coat the gasket with gasket sealer and place in position on cover, then install crankcase front cover to block and torque bolts to specifications. 4. Remove centering tool. NOTE: It is important that centering tool be used to align crankcase front cover so that crankshaft hub or torsional damper installation will not damage seal and to position seal evenly around the balancer or hub surface. 5. I n s t a l l crankshaft torsional damper as outlined. 6. Install oil pan with new gaskets and seals as outlined.
OIL SEAL (FRONT COVER) Replacement ( W i t h Cover Removal)

1. With crankshaft torsional damper removed, install tools as shown in Fig. 6A-34 and remove seal. 2. Install new seal so that open end of seal is toward the inside of cover and drive it into position with ToolJ-8340. (Fig. 6A-35)

1. With cover removed, pry old seal out of cover from the front with screw driver being careful not to distort cover. 2. Install new seal so that open end of the seal is toward the inside of cover and drive it into position with T o o l J - 995. (Fig. 6 A-33)

Fig. 6A-34

Removing O i l Seal (Cover Installed)

6A-18

L-6 Engine

cam lobe. At this point, the push rod will be in its lowest position. 4. Set dial indicator on zero, then rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the push rod is in the fully raised position. NOTE: The primary distributor lead must be disconnected from the negative post on the coil and the ignition switch must be in the ON position. Failure to do this will result in a damaged grounding circuit in the ignition switch. 5. Compare the total lift recorded from the dial indicator with specifications. 6. Continue to rotate the crankshaft until the indicator reads zero. This will be a check on the accuracy of the original indicator reading.
Fig. 6A-35 CAMSHAFT Installing O i l Seal (Cover Installed)

7. If camshaft readings for all lobes are within specifications, r e m o v e dial i n d i c a t o r assembly. 8. I n s t a l l outlined. and a d j u s t valve mechanism as

Measuring Lobe l i f t

NOTE: Procedure is similar to checking valve timing. If improper tion is indicated, measure the lift rod in consecutive order and record

that used for valve operaof each push the readings.

Removal

1. Remove valve lifters. 1. Remove valve mechanism as outlined. 2. Remove crankcase front cover. 2. Position indicator with ball socket adapter on push rod. (Fig. 6A-36) 3. Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the 3. Remove grille. 4. Remove fuel pump. 5. Align timing gear marks then remove the two camshaft thrust plate bolts by working through holes in the crankshaft gear. (Fig. 6A-37) 6. Remove the camshaft and gear assembly by pulling it out through the front of the block. NOTE: Support camshaft carefully when removing so as n o t to damage camshaft bearings.

Inspection

The camshaft bearing journals should be measured with a micrometer for an out-of-round condition. If the journals exceed .001" out-of-round, the camshaft should be replaced. The camshaft should also be checked for alignment. The best method is by use of " V " blocks and a dial indicator (Fig. 6A-38). The dial indicator will indicate the exact amount the camshaft is

Fig. 6A-36

Measuring Camshaft Lobe Lift

(Fig. 6A-39 Checking Camshaft End Play REPLACEMENT 1.002" dial indicator reading.001" to . 6A-40 O i l Nozzle Replacement Fig. out of true. the camshaft should be replaced. (Fig.L-6 Engine 6A- Fig. If it is out more than . 6A-40) 2. 6A-4J Removing Camshaft Gear Inspect the camshaft gear and thrust plate for wear or damage. . 6A-38 Checking Camshaft Al ignment Fig. Drive new nozzle in place (oil hole in vertical position) using a suitable light plastic or rubber hammer. Remove nozzle with pliers. 6A-39) OIL N O Z Z L E Fig. This should be . Measure the camshaft end play.005". 6A-37 Timing Gear Marks Fig.

Check the backlash between the timing gear teeth with a dial indicator. Fig. If gear runout is excessive. 3. If the inspection indicates that the shaft.004" nor more than . 6A-43).003". 8. 5. Install the camshaft and gear assembly in the engine block. 6A-42 Installing Camshaft Gear C A M S H A F T GEAR REPLACEMENT 1. Installation Fig.004" and the crankshaft gear runout should not exceed . Refer to Fig. Install crankcase front cover. 4. being careful not to damage camshaft bearings or camshaft. 2. (Fig. NOTE: Thrust plate must be positioned so that woodruff key and shaft does not damage it when the shaft is pressed out of gear. Install grille. Place the gear on the shaft until clearance shown in Fig. 9. 6A-42. 6A-43 Timing Gear Marks 1. 6A-44 Checking Camshaft Gear Runout 6. 6A-44) The camshaft gear runout should not exceed .6A-20 L-6 Engine Fig. the gear should be removed from the shaft. (Fig. 6A-42 is obtained. oil pan and oil pump . 3. 2. Turn crankshaft and camshaft so that the valve timing marks on the gear teeth will line up (Fig. the gear will have to' be removed and any burrs cleaned from the shaft or the gear will have to be replaced. Push camshaft into position. CAMSHAFT BEARINGS Removal Camshaft bearings can be replaced while the engine is removed for overhaul by removing the following parts: front cover. 7. Install valve lifters.006". To assemble cam shaft gear and thrust plate. 6A-41 for gear removal. 6A-45) The backlash should not be less than . Install fuel pump. Install camshaft thrust plate to block bolts and torque to specifications. gear or thrust plate should be replaced. use an arbor press and Tool as shown in Fig. Check camshaft and crankshaft gear runout with a dial indicator.

6A-47. 6A-46 Removing No. after positioning the tool behind the bearing pull the ring rearward so jaws of tool will expand behind the bearing. 2 and 3 using tools as shown in Fig. Fig. Leave cylinder head and pistons 1. Using tools shown in Fig. Installation Fig. intact. 1. 4. With pilot installed as shown in Fig.L-6 Engine 6A-21 and camshaft. 6A-45 Checking Timing Gear Backlash 1. 2. NOTE: After driving out No. 6A-46. drive out cam bearing No. pull No. 4 bearing. 1. 3 and 2. NOTE: Slide slip ring forward on jaws of tool so that tool will enter behind the bearing. 2 and 3. 6A-46. install pilot to drive out No. With camshaft removed. install bearings No. 2 & 3 Camshaft Bearing . 1.

remove pilot and thread BT-6609-3 onto Handle BT-6609-5 and drive bearing into block until white line on Tool BT-6609-3 is flush with face of block. 6A-47 Removing No.001". Drive bearings No. a new bearing. . both upper and lower halves. 1. For this reason. 3 and 2 in until the white marks on tool are flush with the pilot. you may find one-half of a standard insert with onehalf of a . crankshaft gear may be removed using Tools shown in Fig.6A-22 L-6 En gme Fig.009". If clearances are found to be excessive. will be required. Selective fitting of both rod and main bearing inserts is necessary in production in order to obtain close tolerances. 2. . Fig. To install crankshaft gear use Tools shown in Fig.020" and . Bearings are available in standard size and . . 6A-48 Removing Crankshaft Gear M A I N BEARINGS Main bearings are of the precision insert type and do not utilize shims for adjustment. 6A-49 Installing Crankshaft Gear When a production crankshaft cannot be precision fitted by this method. it is then ground . 6-49. . 4 Camshaft Bearing NOTE: Make sure oil holes are aligned.030" undersize. 4. TIMING GEARS Replacement With camshaft removed.0005" from using a full standard bearing. Fig. 009" .010".001" undersize insert which will decrease the clearance . 6-48.002". To install bearing No.

A Figure "9" will be stamped on the block at the left front oil pan rail. the lower half of the bearing shows a greater wear and the most distress f r o m fatigue. ". the crankshaft will rest on the upper bearings and the total clearance can be measured between the lower bearing and journal. all bearing cap bolts should be at their specified torque. main bearing caps are replaced. Checking Clearance To obtain the most accurate results with Plastigauge. Laminated shims for each cap are available for service. Inspection upside down. it can be assumed that the upper half is also satisfactory. 5. both upper and lower halves should be replaced. 6A-51 Measuring Gauging Plastic undersize on main journals only. shimming may be necessary.L-6 Engine 6A-23 Fig. Remove bearing cap. If the lower half shows evidence of wear or damage. With the oil pan and oil pump removed and starting with the rear main bearings. the surface of the crankshaft journal and bearing should be wiped clean of oil. for any reason. 1. The total clearance can then be measured between the lower bearing and journal. Never replace one-half without replacing the other half. 4. 2. Any engine fitted with a . If the engine is out of the vehicle and . Install the bearing cap and evenly torque the retaining bolts to specifications. A . Shim requirement will be determined by bearing clearance. If upon inspection.009" undersize bearing and . NOTE: To assure the proper seating of the crankshaft. The flattened gauging plastic will be found adhering to either the bearing shell or journal. remove bearing cap and wipe oil from journal and bearing cap. NOTE: If. the crankshaft should be supported both front and rear (damper and flywheel) to remove the clearance from the upper bearing. 2. certain precautions should be observed. If the engine is to remain in the vehicle. On the edge of gauging plastic envelope there is a graduated scale which is correlated in thousandths of an inch.009" undersize crankshaft will be identified by the following markings. Without removing the gauging plastic. the lower half is suitable for use. 3. 6A-50) NOTE: Do not rotate the crankshaft while the gauging plastic is between the bearing and journal. Place a piece of gauging plastic the full width of the bearing (parallel to the crankshaft) on the journal. (Fig. (or its equivalent) a wax-like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface.009" will be stamped on the crankshaft counterweight forward of the center main journal. 6A-50 Gauging Plastic on Journal Fig. In addition. 1. measure its compressed width (at the widest point) In general.010" undersize bearing may be used for precision fitting in the same manner as previously described. preparatory to checking fit of bearings.

W i t h Crankshaft Removal 1. oil pump and spark plugs removed. Install a new r e a r main bearing oil seal in the cylinder block and main bearing cap. If none are found. replace the insert. inspect for burrs or nicks. it will be necessary to regrind the crankshaft journal for use with the next undersize bearing.001".002" undersize bearing may produce the proper clearance. 2. After all bearings have been checked. Without Crankshaft Removal 1. Coat bearing surfaces of new. rotate the crankshaft to see that there is no excessive drag. » 6. Remove the main bearings from the cylinder block and main bearing caps. be sure to fit to the maximum diameter of the journal. Measure at the front end of the r e a r main bearing with a feeler gauge. Install the crankshaft. Proceed to the next bearing.001". With oil pan. interference between the bearing and journal will result in rapid bearing failure. 9. If the clearance is not within specifications. Be sure to measure the journal with a micrometer if the flattened gauging plastic indicates more than . if a bearing is being fitted to an out. Measure crankshaft end play (see specifications) by forcing the crankshaft to the extreme front position. If the bearing clearance is with specifications. then install shims as required. However. 6A-52 Measuring Crankshaft End Play Fig. The rear main journal has no oil hole.6A-24 L-6 Engine Fig.ofround journal (. 6A-52) 10. NOTE: If a new bearing cap is being installed and clearance is less than . Remove and inspect the crankshaft. Always replace both upper and lower insert as a unit.001" max.). 7. Use a small drift punch and hammer to start the upper bearing half rotating out of block. Replace the r e a r main bearing upper half as follows: a. the bearing insert is satisfactory. If the bearing is fitted to the minimum diameter and the journal is out-of-round . A . 3. there is a difference in clearance indicating taper. (Fig. . 4. (Fig. 8. 6A-51) NOTE: Normally. correct size. Replacement NOTE: Main bearings may be replaced with or without removing the crankshaft. main bearings with oil and install in the cylinder block and main bearing caps. If the flattened gauging plastic tapers toward the middle or ends. If not. low spot or other irregularity of the bearing or journal. remove cap on main bearing requiring replacement and remove bearing from cap. 6A-53 Rear Main Bearing Replacement with the graduations on the gauging plastic envelope. 2. main bearing journals wear evenly and are not out-of-round.001" difference.

a cotter pin may be bent as required to do the job. Fig. DO NOT FILE RODS OR ROD CAPS.001" and . If within specifications. Oil new lower bearing and install in bearing cap. The last 1/4" movement may be done by holding just the slinger with the pliers or tap in place with a drift punch. d. If within specifications and a new bearing is to be installed. Remove the bearing cap and . This will roll upper bearing out of block. Install a main bearing removing the installing tool in oil h o l e in crankshaft journal. Use pliers as in removing to rotate bearing into place. remove the connecting rod cap and bearing. bearing and remeasure the clearance. 3. (Fig. If the clearance exceeds specifications. All other crankshaft journals have oil holes. interference between the bearing and crankpin will result in rapid bearing failure. and in . Measure the crankpin for out-of-round or taper with a micrometer. 5. c. measure new or used bearing clearances with Plastigage or its equivalent. bearing cap bolts to 2. a new bearing will be required. If not within specifications.002" undersize for use with new and used standard size crankshafts. correct size. (Bearing showing the above should not be reinstalled). Place a piece of gauging plastic the full w i d t h of the crankpin (parallel to the crankshaft). 6A-54 Gauging Plasfic on Crankpin b. Install the bearing cap and evenly torque nuts to specifications. NOTE: Do not turn the crankshaft with the gauging plastic installed. T o r q u e m a i n specifications. 3. measure the gauging plastic width at the widest point.020" undersize for use with r e conditioned crankshafts. 4. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of block. Inspection and Replacement 1. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of block. Install main bearing cap with arrows pointing toward front of engine. replace or recondition the cranks h a f t . Bearings are available in standard size and . measure the maximum diameter of the crankpin to determine new bearing size required. be sure to fit to the maximum diameter of the crankpin. 6A-53) c. Install the bearing in the connecting rod and cap.001".010" and . Use a pair of pliers (with taped jaws) to hold the bearing thrust surface to the oil slinger and rotate the crankshaft to r e move bearing. . c. With oil pan and oil pump removed. 4. NOTE: If a bearing is being fitted to an out-of-round crankpin. Rotate the bearing into place and remove tool from oil hole in crankshaft journal. NOTE: If such a tool is not available. 5. If the bearing is fitted to the minimum diameter and the crankpin is out-of-round . Inspect the bearing for evidence of wear or damage. 6A-55) 6. 6. 6A-54) b. If clearances are found to be excessive.using the scale on the gauging plastic envelope. d. (Fig. (Fig. Rotate the crankshaft clockwise as viewed from the front of engine.L-6 Engine 6A-25 CONNECTING ROD BEARINGS Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment. select a new. Replace t h e main bearing upper h a l f as follows: a. a. b. Wipe the bearings and crankpin clean of oil.

(Fig. Using Tools J-9510 shown in Fig. . place connecting rod and piston assembly in an arbor press with piston on support. piston pin. 4. 8. After ridge and/or deposits are removed. Remove piston rings by expanding them and sliding them off the pistons.6A-26 L-6 Engine Fig. tap each rod lightly (parallel to the crankpin) to make sure they have clearance. 6A-56 Measuring Connecting Rod Side Clearance 7. Remove assembly from arbor press and remove tools. Remove connecting rod cap and install Tool J-6305 (11/32") on studs. When all connecting rod bearings have been installed. Measure all connecting rod side clearances (see specifications). 6A-57 Removing Connecting Rod and Piston Assemblies 3. With oil pan. Wash connecting rods in cleaning solvent and dry with compressed air. 9. 2. press piston pin out of connecting rod and piston. 2. (Fig. using remover. mark them. turn crankshaft until piston is at the bottom of stroke and place a cloth on top of piston to collect the cuttings. 6A-55 Measuring Gauging Plastic Fig. then. 6A-57) NOTE: It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder. NOTE: Before ridge and/or deposits are removed. 6A-56) CONNECTING ROD AND PISTON ASSEMBLIES Removal 1. between the connecting rod cap and side of crankpin. Inspect connecting rods and connecting rod caps for cylinder identification. NOTE: If connecting rod bearings are being reused. place them in a rack so they may be reinstalled in their original rod and cap. turn crankshaft until piston is at top of stroke and remove cloth and cuttings.. oil pump and cylinder head r e moved. 3. Disassembly Fig. Remove connecting rod bearings from connecting rods and caps. If necessary. connecting rod and piston. Coat the bearing surface with oil. Push connecting rod and piston assembly out of top of cylinder block. 6A-58. use a ridge reamer to remove any ridge and/or deposits from the upper end of the cylinder bore. install the rod cap and torque nuts to specifications. Cleaning and Inspection Connecting Rods 1.

Inspect the piston for cracked ring lands. Replace connecting rods that are damaged. indexing pilot through piston and rod. start piston pin into piston and press on installer until pilot bottoms in support. Place piston on support. .001" wear limit. the piston and piston pin assembly should be replaced. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin. (Fig. 3. 6. Inspect the grooves for nicks or burrs that might cause the rings to hang up. Remove installer from connecting rod and piston assembly and check piston for freedom of movement on piston pin. place support w i t h spring and pilot in place on an arbor press.5 8 Piston Pin Removing Check for twisted or bent rods and inspect for nicks or cracks. scuffed or damaged skirts. 6A. eroded areas at top of the piston. Assembly 1. 2. Because of this.L-6 Engine 6A-27 Fig. If clearance is in excess of the . DO NOT WIRE BRUSH ANY PART OF THE PISTON. 5. Place installer on piston pin. 6 A . Measure piston skirt (across center line of piston pin) and check clearance as outlined under PISTON SELECTION. The piston pin should be measured with a micrometer and the piston pin bore should be measured with a dial bore gauge or an inside micrometer. Pistons Clean varnish from piston skirts and pins with a cleaning solvent. The piston pin clearance is designed to maintain adequate clearance under all engine operating conditions.59) 4. Replace pistons that are damaged or show signs of excessive wear. Using Tool BT-6408. Piston Pins Inspect piston pin bores and piston pins for wear. wavy worn ring lands. the piston and piston pin are a matched set and not serviced separately. Position piston on connecting rod with appropriate side of piston and oiling hole in connecting rod aligned. Piston pin bores and piston pins must be free of varnish or scuffing when being measured. Clean the ring grooves with a groove cleaner and make sure oil ring holes and slots are cleaned. skirts or pin bosses.

consisting of two segments (rails) and a spacer. The top ring is chrome faced or treated with molybdenum for maximum life. Install piston rings as follows: (Fig. All compression rings are marked on the upper side of the ring. 6A-60 Measuring Ring Cap Piston Rings 6. remove by dressing with a fine cut file. 6A-60) 4. Slip the outer surface of the top and second compression ring into the respective piston ring groove and roll the ring entirely around the groove (Fig. 2.. 7. press the ring down into the cylinder bore about 1/4" (above ring travel). 1. 6A-62) NOTE: Tool J-8021 (3-7/8") is available for this purpose. (Fig. . Slip the compression ring in the cylinder bore. Install oil ring spacer in groove and insert anti-rotation tang in oil hole. Fit each compression ring to the cylinder in which it is going to be used. The oil control rings are of the three-piece type. 8. 6A-62 Ring Cap Location 3. / \ 1 " A " OIL RING SPACER GAP (Tang in Hole or Slot within Arc ) "B" Oil RING RAIL CAPS C" k .6A-28 L-6 Engine Fig. If the binding is caused by a distorted ring. the cause should be determined and if caused by ring groove. If binding occurs at any point. do so. When installing compression rings. make sure the marked side is toward the top of the piston. remove the ring and try another for fit. Be sure ring is square with cylinder wall. then. a. Fig. If the gap between the ends of the ring is below specifications. 6A-59 Connecting Rod and Piston Relationship yjT f " V ps ^V. 6A-61) to make sure that the ring is free. If the pistons have not been cleaned and inspected as previously outlined. 5. B „ ^ " A " "D"-j\ ^ / " C " 2ND COMPRESSION RING GAP " D " TOP COMPRESSION RING GAP Fig. check a new ring. Measure the space or gap between the ends of the ring with a gauge. Select rings comparable in size to the piston being used. 6A-61 Checking Ring in Groove Fig.

L-6 Engine 6A-29 Fig. Install top compression ring with gap properly located. 3. (Fig. b. e. 6A-65) Guide the connecting rod into place on the crankshaft journal. Proper clearance of the piston ring in its piston ring groove is very important to provide proper ring action and reduce wear. 4. Install upper steel oil ring rail with gap properly located. f. Install each connection rod and piston assembly in its respective bore. Lubricate connecting rod bearings and install in rods and rod caps. the "ores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry cloth. compress the rings. Install with cylinder wall oiling hole (spit hole) in connecting rod towards camshaft. c. 9. d. 6A-63) Installation Fig. the cause should be determined and if caused by ring groove. then ring with gaps properly located. (Fig. install short pieces of rubber hose over the connecting rod bolts. 6A-63 Measuring Ring Groove Clearance Connecting Rod—Installed Position 2. 6A-64 Fig. (Fig. 6A-64) Using a tool such as J-8307. If binding occurs at any point. Flex the oil ring assembly to make sure ring is free. If binding is caused by a distorted ring. Lightly coat pistons. check a new ring. the clearance between the surfaces of the ring and groove should be measured. This may be accomplished with a hot water and detergent wash or with a light honing as necessary. Hold the ring compres- . Therefore. rings and cylinder walls with light engine oil. Install second compression ring expander. 6A-65 Installing Connecting Rod and Piston Assemblies NOTE: Cylinder bores must be clean before Piston installation. With bearing caps removed. Hold spacer ends butted and install lower steel oil ring r a i l with gap properly located. remove by d r e s s ing groove with a fine cut file. when fitting new rings. After cleaning. NOTE: Be sure ring gaps are properly positioned as previously outlined. 1. Use a hammer handle and light blows to install the piston into the bore.

Measure crankshaft end play with a feeler g a u g e . g. e. this surface is treated with glue. Install the bearing caps and torque nuts to specifications. 3. mark them.Replacement. If necessary. If a connecting rod is ever transposed from one block or cylinder to another. crankshaft pulley and torsional 6. timing chain and camshaft sprocket. 5. not to arrows 1. 9. d. Wash crankshaft compressed air. then lubricate bearing surface with engine oil. Be sure to install new pistons in the same cylinders for which they were fitted and used pistons in the same cylinder from which they were removed. Figs. Retorque all main bearing cap bolts to specifications. Removal 2. first rearward then forward with a lead hammer. R e m o v e damper. refer to CONNECTING ROD BEARINGS. Remove oil pan and oil pump. Check the connecting rod caps for cylinder number identification. Install crankshaft. beginning at the front of the engine. Install main bearing caps with pointing toward front of engine. 6A-48 and 6A-49 illustrate the tools used. b. SPROCKET OR GEAR REPLACEMENT Refer to TIMING GEARS . Remove the connecting rod caps and push the pistons to top of bores. Torque all except r e a r main bearing cap bolts to specifications. Install main bearings in cylinder block and main bearing caps. Install rear main bearing oil seal in cylinder block and rear main bearing cap grooves. Check crankshaft for runout by supporting at the front and rear main bearings journals in " V " blocks and check at the front and rear intermediate journals with a dial indicator (see specifications). then tap end of crankshaft. Install with lip of seal toward front of engine. 4. 2. 10. The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. lbs. mount engine in overhaul stand and clamp securely. f. taper or undersize (see specifications). Remove the oil dipstick. 5. CLEANING AND INSPECTION 1.. Each connecting rod and bearing cap should be marked. Remove the starting motor. Keep oil off parting line surface. 7. . Lubricate lip of seal with engine oil. Remove rubber bolts. Remove main bearing caps and lift crankshaft out of cylinder block. 3. CRANKSHAFT The crankshaft can be removed while the engine is disassembled for overhaul or without complete disassembly as outlined below. hose from connecting rod 11.c. in solvent and dry with 6. Install the crankshaft as follows: a. clutch assembly (if equipped) and flywheel. NOTE: If bearing replacement is required. Replace or recondition the crankshaft if out of specifications.6A-30 L-6 Engine sor firmly against the cylinder block until all piston rings have entered the cylinder bore. (Force crankshaft foward and measure clearance between the front of . Measure dimensions of main bearing journals and crankpins with a micrometer for out-ofround. being careful damage bearing surfaces. With the engine removed from the vehicle and the transmission and/or clutch housing r e moved from the engine. 4. Remove crankcase front cover and if so equipped. Torque rear main bearing cap bolts to 12 ft. Remove the spark plugs. 8. new bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number. This will line up rear main bearing and crankshaft thrust surfaces. Remove rear main bearing oil seal and main bearings from cylinder block and main bearing caps. Installation 1.

remove valve by prying it out with a screw driver. (Fig. Center gauge in cylinder and turn dial to " 0 " . With crankshaft installed. where used. may be replaced at the same time the bushing is replaced. This should be done with a dial indicator. The thrust washer. 6A-66 Measuring Cylinder Bore With the oil filter removed. When distributor shaft to bushing clearance 1. Some engines have a thrust washer at the upper end of the bushing bore. install the r e maining previously removed parts. Inspect the cylinder block for cracks in the cylinder walls. If cylinders were found to exceed specifications honing or boring will be necessary. 6A-68 Replacing Distributor Bearing . 4. 3. Install and seat a new valve by taping it in place. 6A-67 Oil Filter Bypass Valve OIL FILTER BYPASS VALVE INSPECTION AND REPLACEMENT Fig. 5. Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine the out-of-round condition. water jacket valve lifter bores and main bearing webs. Inspect for a cracked or broken valve. 6A-52. Set the gauge so that the thrust pin must be forced in about 1/4" to enter gauge in cylinder bore. Clean and inspect water passages in the cylinder block.L-6 Engine 6A-31 Fig. check the spring and fibre valve for operation. h. Measure the cylinder walls for taper. The lower bushing will ordinarily require only a clearance or wear check during engine overhaul. 6A. NOTE: These plugs may be removed with a sharp punch or they may be drilled and pried out. DISTRIBUTOR LOWER BEARING A N D THRUST WASHER REPLACEMENT CYLINDER BLOCK Cleaning and Inspection The distributor lower bearing is a bronze bushing pressed into the lower side of the engine block. 6A-67) the r e a r mam Dearing and the crankshaft thrust surface). Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces. using a 9/16 thin-wall deep socket. (Fig. out-of round or excessive ridge at top of ring travel. Its upper diameter pilots the distributor shaft and the diameter extending below the block pilots the oil pump. If replacement is necessary.66) Fig. 2. Remove oil gallery plugs and clean all oil passages. Refer to Fig.

Permanently mark the piston for the cylinder to which it has been fitted and proceed to hone cylinders and fit the remaining pistons.6A-32 L-6 Engine exceeds . cylinder bores may be cleaned with a 3. A cylinder bore of less than. 1. 6A-68) 1. Using a drift up through bushing bore. 3. will collapse enough.0035". If it is desired to entirely clean up the bore in these cases.005" taper or wear they can be conditioned with a hone and fitted with the high limit standard size pistons.005" wear or taper may not entirely clean up when fitted to a high limit piston. The finish marks should be clean but not sharp. If the cylinder block inspection indicated that the block was suitable for continued use except for out-of-round or tapered cylinders. NOTE: This will not damage the bushing and tool is designed for this purpose should it occur. After cleaning. If more than . start new washer in position in bore and drive into place using Tool J-9535. 6A. 3. 4. The instructions furnished by the manufacturer of the equipment being used should be carefully followed. When cylinders are to be honed follow the hone manufacturer's recommendations for the use of the hone and cleaning and lubrication during honing. Before using any type boring bar. 2. REPAIRS Cylinder Conditioning The performance of the following operation is contingent upon engine condition at time of repair. (Fig. drive thrust washer (if installed) out of bore and remove from block. 6. 2. to slightly seize the installer arbor. free from imbedded particles and torn or folded metal. the cylinder bores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry cloth. If thrust washer was removed. they should be bored and honed to the smallest oversize that will permit complete resurfacing of all cylinders. The cylinder should be bored to the same diameter as the piston and honed to give the specified clearance. Position bushing and driver to block and drive the bushing in position. It is possible that the bushing with minimum I. which is determined by tool bottoming against the block. Otherwise. Install Tool J-9534 into bushing and using a slide hammer. CYLINDER H O N I N G 1. remove installer tool using slide hammer in driver bolt hole of driver handle. This is very important. Using Tool J-9535 with driver-bolt in driver handle. (Fig. remove the bushing.D. they can be conditioned by honing or boring. it will be necessary to rebore for an oversize piston. If this happens. When finish honing a cylinder bore to fit a piston. hot water and detergent wash. CYLINDER BORING 2.005" taper or wear. Clean bushing bore in block and check for burrs or damage. 6A-69 Cylinder Finish Marks If the cylinders were found to have less than . the hone should be moved up and down at a sufficient speed to obtain very fine uniform surface finish marks in a cross-hatch pattern of approximately 45° to 65° included angle. When pistons are being fitted and honing is not necessary. 7. the cylinder bore should be thoroughly cleaned and the piston selected for the individual cylinder checked for correct fit. NOTE: Hone cylinders as outlined under "Cylinder Honing and Piston Fitting". 5. install driver into new bushing from large inside diameter. the top of the cylinder block should be filed off to remove any dirt or burrs. Fig. The piston to be fitted should be measured with a micrometer. the boring bar may be tilted which would result in the rebored cylinder wall not being at right angles to the crankshaft. measuring at the center of the piston skirt and at right angles to the piston pin. during installation. the bushing should be replaced as follows with oil pump and distributor removed. . Remove tool from bushing.69) 4. Occasionally during the honing operation.

8957" . Mark the piston to identify the cylinder for which it was fitted.9037" 3. Cylinders should not be cleaned with kerosene or gasoline.001" 3. Check USED piston to cylinder bore clearance as follows: a. remove the flywheel.8750" 3. Locate piston to bore clearance on Piston Selection Chart. 3.9057" 4. 6A-70) and determine if piston to bore clearance is in the acceptable range. If any of the abrasive material is allowed to remain in the cylinder bores. . check Piston Size Chart and determine if a new piston can be selected to fit cylinder bore within the acceptable range. Coat thread end of bolts with sealer then install bolts and torque to specifications. (Fig.8780" Oversize . b. If used piston is not acceptable. (Fig. It is extremely essential that a good cleaning operation be performed. 2. .8937" 3. Measure the "Piston Diameter" (at skirt across center line of piston pin). Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance". Clean the mating surfaces of flywheel and crankshaft to make certain there are no burrs. 6A-70 Piston Selection Chart MANUAL Fig. measure new piston diameter (across center line of piston pin) then hone cylinder bore to correct clearance (Preferable Range). 6A-72 Flywheel Installation (Typical) d. e thoroughly clean the cylinder bores with hot water and detergent.8760" 3. PISTON SIZES AVAILABLE Std.L-6 Engine 6A-33 NOTE: Handle the pistons with care and do not attempt to force them through the cylinder until the cylinder has been honed to correct size as this type piston can be distorted through careless handling.8760" 3. 2. If cylinder bore must be reconditioned. Scrub well with a stiff bristle brush and rinse thoroughly with hot water. PISTON SELECTION 1. Installation 1. the flywheel must be installed with the flange collar to transmission side. Clean the remainder of the cylinder block to remove the excess material spread during the honing operation. Install flywheel on crankshaft and position to align dowel hole of crankshaft flange and flywheel. 6A-72) NOTE: On Automatic Transmission equipped engines. Measure the "Cylinder Bore Diameter" with a telescope gauge (2-1/2" from top of cylinder bore). The bores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry cloth. it will rapidly wear the new rings and cylinder bores in addition to the bearings lubricated by the contaminated oil. 3.020" 3. c. FLYWHEEL Removal With transmission and/or clutch housing and clutch removed from engine. Fig.030" 3.

lbs. 80 in. Fig. Lower engine. Raise transmission to release weight from mount. 20 ft. 5. 20 ft. lbs. lbs. lbs. lbs. 60 ft. 125 in. install through bolt and tighten all mount bolts to specified torques. lbs. then remove mount and spacer. lbs. lbs. lbs. 20 ft. 55 in. Rear Mount Replacement 1. then install assembly on crossmember. 80 in. 15 ft. lbs. 6A-73) a r e the nonadjustable type and seldom require service.6A-34 L-6 Engine mount through bolt. 55 in. Raise engine to release weight from mount. Spark Plug . lbs. 2. then remove stop bracket and mount from frame bracket. Remove nut. lbs. 5. lbs. lbs. lbs. 4. 70 in. lbs. 6A-73 ENGINE MOUNTS Engine Mounts Engine m o u n t s (Fig. spacer then engine TORQUE SPECIFICATIONS SIZES APPLICATION TORQUE 1/4-20 11/32-24 5/16-18 3/8-16 7/16-14 7/16-20 1/2-13 1/2-14 1n 7 ?n 14MM Camshaft Thrust Plate Crankcase Front Cover Flywheel Housing Pans Oil Pan (To Crankcase) Oil Pan (To Front Cover) Oil Pump Cover Rocker Arm Cover Connecting Rod Cap Clutch P r e s s u r e Plate Oil Pan (To Crankcase) Oil Pump Push Rod Cover Water Pump "Distributor Clamp Flywheel Housing Manifold (Exhaust to Inlet) Manifold Clamp (Outer) Manifold Clamp (All Others) Thermostat Housing Water Outlet Main Bearing Cap Flywheel Cylinder Head Temperature Sending Unit Oil Filter Oil Pan Drain Plug . 80 in. 95 ft. 6. Install stop bracket and new mount on frame bracket. 25 ft. lbsT 30 ft. . align and start crossmember to mount bolts. . . Remove mount to transmission bolts. 3. 2. 3. Front Mount Replacement 1. Lower transmission and tighten all mounting bolts to specified torques. stop bracket and frame bracket assembly from crossmember. lbs. 80 in. washer. While lowering transmission. 4. 20 ft. 35 ft. lbs. lbs. 65 ft. Install spacer and new mount on transmission. lbs. 30 ft. lbs. 25 ft.~ Hand Tight 20 ft. 80 in. Remove crossmember to mount bolts. 115 in. because of the added strain placed on other mounts and drive line components. lbs. 30 ft. lbs. lbs. Broken or deteriorated mounts should be replaced immediately. 10 ft. lbs. Remove mount.

9273" .66" Lbs. Hydraulic 1.0135" 2217" 2217" 1... @ In Open 180 .0027" Exhaust 0015" .2983" .Engine Specifications 6A-35 L-6 ENGINE SPECIFICATIONS GENERAL DATA Displacement Horsepower @ rpm Torque @ rpm Bore Stroke Compression Ratio Firing Order CYLINDER BORE Diameter Out-of-Round Taper PISTON Clearance .3/32" Stem Clearance Intake 0010" .A. . . Hi Limit Production + .5:1 1-5-3-6-2-4 3.27" Installed Height ± 1/32" 1-21/32" Damper Free Length N.004" Max.A.8692" 0015" Max.000" 001" Max. 1/32" . Seat Width Intake . 004" Max. 001" Max. of Coils N.001" Hi Limit Production + .2.1/16" Exhaust 1/16" .2993" 001" Max.64 @ 1.001" Hi Limit Production + .8682" . . .8775" 002" Max.2. 0085" .0016" (Interference) Diameter .. . 0025" Max. .0032" Valve Spring Free Length 1.8745" . 005" Max. 002" .1. 001" Max..90" Pressure Closed 56 .53" 8.001" Max.006" 1..3. PISTON RING Groove Clearance Gap Groove Clearance Gap PISTON PIN Diameter Clearance Fit In Rod CRANKSHAFT Main Journal Main Journal Main Bearing Clearance Crankshaft End Play Crankpin Rod Bearing Clearance Rod Side Clearance CAM SHAFT Lobe Lift ± . Approximate No. .01" 9270" .75:1 Intake One Turn Down From Zero Lash Exhaust One Turn Down From Zero Lash Face Angle (Intake and Exhaust) 45° Seat Angle (Intake and Exhaust) 46° Seat Runout (Intake and Exhaust) 002" Max. Taper Out-of-Round 2.. 0008" .192 @ 1.999" .01" Hi Limit Production + ..002" Journal Diameter Camshaft Runout VALVE SYSTEM Lifter Rocker Arm Ratio Valve Lash Intake Exhaust : Diameter Taper Out-of-Round 250 150 @ 4200 235 @ 1600 3-7/8" 3.

003" O. VALVE GUIDE REAMER J-5830-3 .6A-36 Tools BT-6606 BT-6225 BT-6618 BT-6310 S-141 BT-6613 BT-6513 BT-6619 BT-6611 BT-6607 J-8614 BT-6408 BT-6614 BT-6413 BT-6612 ENGINE LIFT CHAIN COOLING SYSTEM TESTER CLUTCH PILOT BEARING INSTALLER CARBURETOR FLOAT GAUGE CARBURETOR FUEL INLET NUT WRENCH ADAPTER FOR NEEDLE AND SEAT TESTER CARBURETOR NEEDLE AND SEAT CHECKER CLUTCH PILOT BEARING REMOVER CRANKSHAFT PULLEY INSTALLER (V-8) EXH. DISTRIBUTOR BUSHING INSTALLER DISTRIBUTOR BUSHING REMOVER FRONT COVER CENTERING GAUGE (L-6) CLUTCH PILOT BUSHING REMOVER (L-6) FRONT SEAL REMOVER PILOT FOR TOOL BT-6406 CAMSHAFT BEARING SET J-22227 J-21795 J-8810 J-8880 J-5715 J-6036 J-9535 J-9534 J-21742 J-1448 BT-6406 J-9395 BT-6609 Fig.7 4 Tools .S.003" O. VALVE GUIDE REAMER J-5830-2 .S.S. ROCKER ARM STUD REAMER .030" O.S. MANIFOLD HEAT RISER BUSHING SET CRANKSHAFT PULLEY REMOVER PISTON PIN TOOLS PISTON PIN ADAPTER (L-6) VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR ADAPTER BT-6616 J-7583-3 BT-6610 BT-6601 J-5154 J-5830 CRANKSHAFT PULLEY REMOVER PILOT SCREW (USED WITH J-8614) CRANKSHAFT PULLEY AND GEAR REMOVER PLATE SCREW CRANKSHAFT TIMIJNIG GEAR AND FRONT OIL SEAL INSTALLER (L-6) J-5830-1 .S. VALVE GUIDE REAMER CAMSHAFT GEAR REMOVAL PLATE CAMSHAFT GEAR INSTALLER CAMSHAFT GEAR REMOVER VALVE ROCKER ARM STUD INSTALLER ROCKER ARM STUD REAMER . 6 A .013" O.015" O.

it will be necessary to refer to Section 6L of this manual. The engine specifications are listed at the back of this section. . The 330. are very similar. VALVE GUIDES REAMING PROCEDURE REPLACING VALVE SPRING (HEAD ON ENGINE) OIL PAN (330 & 425 CU. If the engine being serviced is equipped with K-19. ENGINE ASSEMBLY Removal 1. in. engines. unless otherwise specified. with the exception of cylinder bore size. the service procedures. . . unless otherwise indicated. Drain radiator. The left bank of cylinders (as viewed from the driver's seat) are numbered (from front to rear) 1-3-5-7. Cylinders in the right bank are numbered (from front to rear) 2-4-6-8. 6B-101) The required engine maintenance. (Fig. IN. engine unit numbers and engine identification is outlined in Section 0 of this manual.All Series V-8 Engine 6B-1 V-8 ENGINE CONTENTS OF SECTION 6B Subject P°ge Subject Page DESCRIPTION ENGINE ASSEMBLY REMOVAL INSTALLATION ENGINE MOUNTING INTAKE MANIFOLD EXHAUST MANIFOLD MANIFOLD HEAT CONTROL VALVE. IN. The illustrations used throughout this section are typical of all three V-8 engines. Because of the similarity between the three engines. The removal and installation of various engine parts covered in this section do not comprehend the installation of K-19 (Air Injection Reactor System).) OIL PUMP CONNECTING ROD AND PISTON ASSEMBLY ROD BEARINGS ROD ASSEMBLY 6B-1 6B-1 6B-1 6B-2 6B-4 6B-4 6B-5 6B-6 6B-6 6B-7 6B-8 6B-8 6B-10 6B-10 6B-13 6B-13 6B-14 6B-15 6B-15 6B-15 6B-17 6B-18 6B-19 6B-19 6B-20 6B-21 PISTON MEASURING PISTON CHECKING CYLINDER BORE CLEANING PISTON RINGS RING TOLERANCE PISTON RING AND RAIL GAP SIDE CLEARANCE RING IDENTIFICATION AND INSTALLATION ROD AND PISTON ASSEMBLY PISTON PINS CRANKSHAFT PULLEY HARMONIC BALANCER FRONT COVER OIL SEAL TIMING CHAIN AND GEARS CHECKING VALVE TIMING WITHOUT REMOVING FRONT COVER CAMSHAFT CAMSHAFT BEARINGS CAMSHAFT AND OIL GALLEY PLUGS CRANKSHAFT MAIN BEARINGS REAR MAIN OIL SEAL PILOT BEARING FLYWHEEL FUEL PUMPS TOOLS SPECIFICATIONS 6B-22 6B-22 6B-22 6B-23 6B-23 6B-23 6B-23 6B-23 6B-23 6B-23 6B-24 6B-26 6B-26 6B-27 6B-28 6B-28 6B-28 6B-29 6B-30 6B-32 6B-33 6B-33 6B-36 6B-37 6B-37 6B-39 6B-40 6B-41 V . will be combined.) OIL PAN (400 CU. VALVE COVER ROCKER ARMS VALVE LIFTERS OPERATION ASSEMBLY AND VALVE LIFTER LEAK-DOWN TEST VALVE LIFTER DIAGNOSIS CYLINDER HEAD AND GASKET VALVES AND SPRINGS (HEAD REMOVED) MEASURING VALVE STEM HEIGHT .8 ENGINE DESCRIPTION The same basic V-8 engine is used in all series. . 400 and 425 cu.

marking hinge for reassembly. upper radiator support and coil. 6B-102) NOTE: line. Raise car. power steering pump hoses (as necessary). 9. Fill radiator. converter to flywheel. 6. converter to flywheel. 3. engine to body ground strap.6424. On 34 through 38 Series install Engine Support Bar BT. Reconnect radiator hoses. 10. 5. Remove engine mount through bolts and support engine. starter cable at junction block. heater hoses. Connect exhaust pipes to manifold. Remove Converter Holding Tool J-21654 and replace torque converter cover. Remove six bolts. transmission to engine. fuel hose from fuel line. transmission to engine. 8. wiring and accelerator linkage. Replace three bolts. 5. Remove hood. Disconnect battery. Locate engine dowels into transmission and position through bolts into mounts and tighten. 8. engine to body ground strap. (Fig. 6B-102 Engine Lift Fixture Installation 1. power steering pump hoses (as necessary). wiring and accelerator linkage. Fig. 12. Install and align hood. heater hoses. 7. Remove torque converter cover and install Converter Holding Tool J-21654. On 52 through 86 Series install Engine Support Bar BT-30-16. 10. Use Adapters BT-6424-2. vacuum hoses. vacuum hoses. 11. Fasten Chain BT. fan blade.6606 to engine. 6B-101 Cylinder Numbers 2. 9. 4. starter cable at junction block. . 13. Replace fan pulley. Be careful of vacuum modulator 13. 2. Lift engine and secure transmission chain support to frame. 4. coil and upper radiator support. 11. 12. Lower car. Connect battery. Remove transmission support chain. Disconnect exhaust pipes at manifold. Remove three bolts. 3. Disconnect radiator hoses. 7.6B-2 V-8 Engine All Series Fig. 14. Replace six bolts. Secure Lift Chain BT-6606 to engine. Lower car and remove lift chain. fuel hose to fuel line. 6. disconnect Engine Support Bar and remove engine. Remove fan blade and fan pulley.

6B-103 Engine Mounting (52 through 86 Series) Fig. 36 and 38 Series) .All Series V-8 Engine 6B-3 Fig. 6B-104 Engine Mounting (34.

8. then disconnect upper radiator hose and thermostat bypass hose from water outlet. Also. NOTE: The 400 and 425 cu. and vacuum lines from 1. INTAKE MANIFOLD Removal 1. engines use a one-piece intake manifold gasket as 5. Fig. Clean machined surfaces of cylinder head and intake manifold with a putty knife. Install end seals. Disconnect temperature gauge wire. in. Drain radiator. Coat both sides of gasket sealing surface that seal the intake manifold to the head with 1050026 Sealer and position intake manifold gasket.6B-4 V-8 Engine All Series ENGINE M O U N T I N G 7. then rernov manifold with carburetor attached. 6B-105 Engine O i l Flow . in. Remove intake manifold bolts. Remove air cleaner assembly. 4. Use care not to gouge or scratch machined surface. disconnect heater hose at rear of manifold. engines to provide removal clearance. 9. Disconnect and/or remove generator. 6. if car is so equipped. being sure that ends are positioned under cylinder heads as shown in Fig. Remove coil mounting bolt. Remove fuel carburetor. 6B-103 and 6B-104. NOTE: It will be necessary to remove the distributor on 400 and 425 cu. 2. Installation Refer to Figs. Disconnect throttle linkage. power steering pump and air conditioning compressor brackets as necessary. 6B-106. 3. 2. Wires may be left connected to coil if desired.

Install fuel and vacuum lines. lbs. Clean manifold and cylinder head machined Showa The 330 cu. Position intake manifold on engine and connect thermostat bypass hose to water pump. 8. Connect upper radiator hose. Remove the crossover pipe (disconnect exhaust pipe if equipped with dual exhaust). LBS. CHOKE HEAT STOVE Fig. 3. PERIODIC M A I N T E N A N C E . in. 6B-106 Intake Manifold Gasket EXHAUST MANIFOLD Removal 1. washers and locks and remove the manifold. Fig. 2. disconnect the exhaust pipe. For the right manifold. 6B-108 shows an exploded view of the choke heat stove. Connect temperature gauge wire.7. FT. gaskets. Straighten lock tabs and remove the manifold to head attaching bolts. 4. (Fig. R e f e r to Section 0. 4. for c o o l i n g system recommendations. 6B-107 Intake Manifold Torque Sequence . Fill cooling system. spark plug wires. engine uses two 3. 5. Dip intake manifold bolts in engine oil and torque alternately to 35 ft. TORQUE INTAKE MANIFOLD ATTACHING BOLTS 35 FOLLOWING THE ABOVE RECOMMENDED SEQUENCE. NOTE. 6B-107) Position coil and install mounting bolt. throttle linkage and install air cleaner assembly. Fig. 6. heater hose.

6B-108 Intake Manifold Choke Heat Stove Scribing Exhaust Manifold VALVE M A N I F O L D HEAT C O N T R O L surfaces with a putty knife. lbs. Disconnect spark plug wires and move away from valve cover. Reconnect disconnected parts. Bend bolt locks to retain bolts. 2. i. 6B-I09 Heat Control Valve Installation . Installation Refer to Figs. Install manifold to head bolts and torque to 25 ft. 6B-109. 3. 6B-110 Fig. Fig. 6B-110 and 6B-111.6B-6 V-8 Engine All Series Fig. Disconnect positive crankcase from right valve cover. Use care not to gouge or scratch machined surfaces. VALVE COVER Removal 1. ventilation 2.

6B-111 Heat Control Valve Operation 3. Remove valve cover to cylinder head attaching screws. 35 ft. lbs. 7/16" thread ROCKER ARM ASSEMBLIES (Fig. Torque valve cover attaching screw -to 7 ft. Remove valve cover. Installation Reverse removal procedure. Fig. torque attaching bolts as follows. lbs. pivot and rocker arms. 5/16" thread 3/8" thread 25 ft. 6B-112) Removal 1. For mounting brackets. 2. lbs. 50 ft. Remove rocker arm.All Series V-8 Engine 6B-7 Fig. lbs. flanged bolts. 6B-112 Cylinder Head Exploded View . NOTE: Remove each set (one set per cylinder) as a unit. Remove accessory mounting brackets as necessary and remove valve cover.

3. Position a set of rocker arms (for one cylinder) in the proper location. bolts to 20 ft. Torque Fig. 6B-114 Valve Lifter Operation side of the lifter body which indexes with a groove and hole in the lifter plunger. 6B-113 Rocker Arm Pivot Usage Installation 1.6B-8 V-8 Engine All Series Fig. VALVE LIFTERS Operation . (Fig. The force of the valve spring which is exerted on the plunger through the rocker arm and push-rod causes a slight amount of leakage between the plunger and lifter body. lbs. Coat wear points with 1050169 Lubricant and install the pivots. Oil is supplied to the lifter through a hole in the Fig. Install the hardened flanged bolts. lbs. (Fig. pushing up the push-rod to open the valve. the ball check is held against its seat in the plunger by the ball check spring which traps the oil in the base of the lifter body below the plunger. This "leak-down" allows a slow escape of trapped oil in the base of the lifter body. The plunger and lifter body then raise as a unit. 6B-114) When the lifter begins to ride up the cam lobe. 6B-115 Valve Lifter Cutaway . 6B-113) 4. Oil is then metered past the oil control valve in the lifter. through the push-rods to the rocker arms. Torque bolts to 35 ft. 2. As the lifter rides down the other side of the cam lobe and reaches the base circle NOTE: Both lifters should be in closed valve position when installing nuts.

Remove valve covers. Use of Tool BT-6407 will aid in removal of varnished lifters. 6B~ 116) Disassembly After lifters are disassembled. all parts should be cleaned in clean solvent.rods. A small particle of foreign material under the ball check valve will cause malfunctioning of the lifter. 6B-116 Removing Valve Lifter or "valve closed" position. Allow five minutes for solution to remove varnish. then remove. 2. NOTE: Carburetor cleaning solvent should be used in a well ventilated room. unless the leak-down rate is not within specifications. replace with a new lifter assembly. (Fig. the plunger spring quickly moves the plunger back (up) to its original position. Remove retainer spring with Tool BT-31 or small screwdriver. This restores the lifter to zero lash. Remove lifters. NOTE: Do not condemn valve lifters that have a slight gap or show evidence of leakage where the lifter foot is welded to the lifter body. check the lifter foot for abnormal wear as follows: 1. then remove ball and spring. allow lifter to soak in carburetor cleaning solvent for approximately five minutes. rocker arm assemblies and push. Remove intake manifold and gasket. burrs or scoring of parts. Remove plunger and plunger spring. 2. (See VALVE LIFTER LEAK-DOWN) Whenever lifters are removed. If either the body or plunger is defective. Avoid contact with skin and prolonged breathing of fumes. Remove push-rod seat and oil control valve.All Series V-8 Engine 6B-9 Fig. This movement causes the ball check to open against the ball spring and oil from within the plunger is drawn into the base of the lifter. . If plunger is stuck tight. Available Tool BT-6438 can be used to remove plunger. On varnished lifters. 3. Cleaning and Inspection NOTE: Valve lifters and push-rods should be kept in order so they can be reinstalled in their original position in the cylinder block. apply carburetor cleaning solution to lifter body. 4. 4. Remove ball check retainer from plunger. Close inspection should be made for nicks. Removal 3. 1.

If leak-down tolerance is within specifications. Rotate reservoir one revolution every two seconds and time the indicator from the start to the stop line. Lower tester ram until it contacts the steel ball. 13. Allow ram to move downward by its own weight until air bubbles disappear. check for light between the straight edge and lifter foot. Install plunger retainer. Adjust ram screw so that it contacts the steel ball in the push-rod seat when the pointer is at the start line.59 and leak-down tested before placing into service. (Fig. If light indicates a flat or concave surface of the lifter foot. 3. 12. This condition is normal. the lifter should be replaced and the camshaft inspected for wear. Wear at the CENTER of the cam base circle is NORMAL. 6B-117 Valve Lifter Exploded View Fig. then. Install Adapter 105-2 in reservoir of Tester BT-60. Raise arm. allow ram to bleed down lifter until retaining groove is exposed. Assembly and V a l v e Lifter Leak-Down Test NOTE: Lifters must be assembled while submerged in Hydraulic Lifter Test Fluid BT. It will take a few seconds for the lifter to fill after the engine is started. The camshaft should be replaced ONLY when wear is present across FULL WIDTH of cam base circle. 11. 3. 9. Momentarily Noisy When Car is Started: 4. 10. Place assembly into the tester cup. Place a straight edge across the lifter foot. then position oil control valve and push-rod seat onto plunger. spring over ball check 1. 1. Fig. Raise ram. V a l v e Lifter Diagnosis 2. 5. 2. NOTE: Do not attempt to expell air from lifter by pumping on ram. then allow to lower as in Step 7 Repeat this procedure several times or until all air is expelled from lifter.OB-10 V-8 Engine All Series 1. Hold plunger vertically to prevent cocking spring. After all air is expelled. fill reservoir with Hydraulic Lifter Test Fluid BT-59. Assemble ball check and retainer into plunger. (Fig. Oil drains from the lifters which are holding the valves open when the engine is not running. 6B-118) Allowable leak-down rate is six seconds minimum for used lifters and 9 to 60 seconds for new lifters. Hold plunger with spring up and insert into lifter body. While holding the lifter at eye level. Position the 1/4" steel ball on the push-rod seat. NOTE: Lifter foot must be clean and dry. 6B-117) Make sure retainer flange is pressed tight against bottom of recess in plunger. Install retaining ring. 6B-118 Valve Lifter Bleed Down Test . 7. 8. 1/2" below top of reservoir. 6. the lifter can be placed in service without removing test fluid. then start test by resting ram on steel ball.

damper clicking on (8) Distorted lock plate. a. Observe rocker arm pad for excessive wear or excessive off square. a. Correction: Clean the lifter and inspect. check for an off square valve spring. Noise will change. With gloved hand. If spring is off square more than 1/16" in free position. (9) Two barrel engine push-rod in a four barrel engine. Quiet With Cold Oil or As Engine Speed is Increased: Insert a . See PERIODIC MAINTENANCE Section. (6) Excessive valve face runout. When foam is pumped into the lifters.All Series V-8 Engine 6B-11 Correction: Fill until proper oil level is obtained. a. Correction: The lifter must be replaced. (5) Off square rocker arm pad. Crank engine until noisy valve is off its seat. 2. Fig. or 30 to 35 mph " D " range and is best described as a hashy sound. either becoming louder or disappearing completely. (Fig. it may be entirely gone or appear as a light ticking noise in one or more valves. Noisy at Idle Becoming Louder as Engine Speed is Increased to 1500 rpm. If correction is obtained. or it may be caused by dirt. Noisy at High Car Speeds and Quiet at Low Speeds. Repeat until valve becomes quiet. Disappearing When Engine Speed is Increased: Intermittent clicking may be an indication of a flat or pitted ball. 6B-119 Valve Spring Checking valve stem to guide (3) Excessive valve seat runout. Correction: Drain oil until proper level is obtained. See PERIODIC MAINTENANCE Section. This will also rotate valve. replace spring. locate noisy valves by increasing engine speed slightly above idle. Remove valve covers and while listening with a stethoscope. Correction: 4. (4) Off square valve spring. (Fig. High oil level . push sideways on valve spring. b.Oil level above the " F u l l " mark allows crankshaft counterweights to churn the oil into foam. At slow idle. 3. (7) Valve spring retainer. they will become noisy since a solid column of oil is r e quired for proper operation. If ball is defective. It becomes most noticeable in the car at 10 to 15 mph " L " range. replace lifter. 6B-120) . 5. Some noise will be present in all valve locations. Low oil level . about 1500 rpm. Replace as required. Noisy At Slow Idle or With Hot Oil.015" feeler gauge between the rocker arm and valve stem. Rotate spring. It is necessary to determine which are actually responsible for the noise. 6B-119) b. If noise momentarily disappears and then re-appears after a few seconds with the feeler still inserted.Oil level below the "Add" mark allows the pump to pump air at high speeds which results in noisy lifters. It is caused by one or more of the following: (1) Badly worn or scuffed valve tip and rocker arm pad. Occasionally this noise can be eliminated by rotating the valve spring and valve. Intermittently Noisy on Idle Only. it is an indication that the lifter leak-down rate is too fast. (2) Excessive clearance. This noise is not connected with lifter malfunction.

2. check for excessive valve stem to guide clearance. Valves Noisy Regardless of Engine Speed. run the engine at a high speed. a. Correction a. If this method does not quiet the lifter. 6B-121. Lifter should be replaced. b. (4) Defective lifter. With transmission in NEUTRAL and parking brake on. b. 3. Position rocker a r m s . Excessive wear of the spherical surface indicates one of the following conditions. The oiling system to the push-rod should be checked. If valve lash is present. Observe upper end of push-rod. 6B-120 Rocker Arm Wear Baffle Installation Checking of the above four items: Remove the rocker arm assemblies then proceed as follows: 1. The push-rod and rocker arm must be replaced. pivots. If correction is not obtained. 2. Installation c. . If necessary. Improper lubrication to the push-rod. (3) Lifter plunger stuck in down position due to dirt or varnish. strike the rocker arm above the push-rod with a mallet while the engine is idling. Valve lash indicates one of the following: (1) Worn push rod.027" longer than two barrel 330 cubic inch engine push-rods and are identified by a blue band at each end. 6B-121. Check for valve lash by turning engine so the piston in that cylinder is on top dead center of firing stroke. If valve lash exists and push-rod and rocker arm are okay. (2) Worn rocker arm. If push-rod appears in good condition and has been properly lubricated.6B-12 V-8 Engine All Series Fig. The push-rod and rocker arm must be replaced. Install manifold gaskets and manifold. NOTE: Four barrel 330 cubic inch engine push rods are . This condition can be caused by foreign particles or excessive valve lash. Install baffle (if removed) in 400 and 425 cubic inch engines as shown in Fig. replace rocker arm and recheck valve lash. 3. 6B-121 Fig. correct as required. trouble is in the lifter. 6. lock plates. Improper hardness of the push-rod ball. the push rod can be freely moved up and down a certain amount with rocker arm held against valve. 1. Install lifters and push-rods into original position in cylinder block. washers and nuts on cylinder head as shown in Fig. This method of correction has proven successful for dislodging a foreign particle which is preventing the ball from seating properly.

Ail Series

V-8 Engine

6B-13

NOTE: Loosen or remove any accessory brackets which interfere. 5. Remove ground strap from head. right cylinder

6. Remove cylinder head bolts and remove cylinder head with exhaust manifold and rocker arms attached. NOTE: DO NOT BEND OIL DIP STICK TUBE WHEN REMOVING OR INSTALLING LEFT CYLINDER HEAD.
Installation

Head gasket should be coated on both sides with Part No. 1050026 Sealer or equivalent before installation. Clean and dip entire cylinder head bolts in engine oil. Torque head bolts to 80 ft. lbs. (Fig. 6B-123) and torque exhaust manifold to head bolts to 25 ft. lbs. Bend exhaust manifold bolt locking tabs.
Fig. 6B-122 Cylinder Head Exploded View VALVES A N D SPRINGS (HEAD REMOVED)

4. Install intake manifold and valve cover, connect spark plug wires and install air cleaner.

CYLINDER HEAD AND GASKET
Removal

NOTE: Valves used in Starfire and 400 cu. in. engines are .030" longer than other V-8 valves and are identified as shown in Fig. 6B-124.
Removal

1. Drain radiator and cylinder block. 2. Remove intake manifold. 3. Disconnect exhaust crossover pipe for left side and/or crossover pipe and exhaust pipe for right side. 4. Remove valve cover.

1. Remove spark plugs and exhaust manifold. 2. Remove valve keys by compressing valve spring with a tool such as J-7541 or OTCCF-11. 3. Remove valve spring retainers and springs. 4. Remove oil deflectors from valve stems.

Fig. 6B-123

Cylinder Head Torque Sequence

6B-14

V-8 Engine

All Series

TYPE INTAKE . .-. - - ^ ^ms^ i
t

ENGINE USAGE 330 CU.IN. 400 CU. I N .

PAINT CODE YELLOW RED

FORGED HEAD LETTER DIA. "01" "SI" "04" "S4" "07" "S7" "06" "S6" "El" "Tl" "E2" "T2" "E3" "T3" 1.875 2.062 2.000 2.000 1.562 1.625 1.625

LENGTH 4.620 4.593 4.563 4.593 4.620 4.557 4.587

SEAT ANGLE

45° 30° 30° 30° 45° 45° 45°

INTAKE INTAKE INTAKE EXHAUST

425 CU.IN. GREEN (Exc. Starfire) 425 CU. IN. (STARFIRE) 330 CU.IN. BLACK YELLOW

e *>

^

EXHAUST EXHAUST

425 CU 0 IN. GREEN (Exc. Starfire) 400 CU. I N . 425 C U . I N . (STARFIRE) BLACK

Fig. 6B-124 Valve Identification

5. Remove valves. Keep valves separated so they can be installed in their original locations. (Fig. 6B-125)
Installation

1. Install valves in their respective guides. 2. Install new oil deflectors Position deflectors down as valve stem. The deflectors sition themselves when the 3. Position valve over valve stem. far as possible on will correctly poengine is started. stems.

clean carbon from cylinder heads and valves using care not to gouge or scratch machined surfaces. A soft wire brush is suitable for the purpose. Whenever valves are replaced or new valves installed, the valve seats must be reconditioned. If valve guide bores are worn excessively, they can be reamed oversize. This will require replacement of the valves. The guide bores should be reamed before grinding the valve seats. Valve clearance in guide bore should be .001" to .004".
Measuring Valve Stem Height

springs over valve

4. Install valve spring retainers; then, compress springs with a tool such as J-7541 or OTCCF-11 and install valve stem keys. 5. Check valve springs and keys to be sure they are properly seated. 6. Install exhaust manifold. Torque bolts and nuts to 25 ft. lbs. Bend exhaust manifold bolt lock tabs. 7. Set spark plug gap (.030"). Lubricate plug threads with one drop of SAE 10W30 oil and re-install plugs. Torque to 35 ft. lbs.
Reconditioning Valves

Whenever a new valve is installed, or after grinding valves, it will be necessary to measure valve stem height as follows:

When reconditioning valves and valve seats,

Fig. 6B-125

Valve Location

All Series

V-8 Engine

6B-15

Fig. 6B-127 Measuring Valve Retainer Height Fig. 6B-126 Measuring Valve Stem Height

Install Gauge BT-6428 as shown in Fig. 6B-126. There should be at least .035" clearance (on all except Starfire and 400 cu. in. engines which have a clearance of at least .005") between gauge surface and end of valve stem. (Valve stem can be gauged with or without the valve spring r e tainer on the valve.) If clearance is less than specifications, remove valve and grind tip of valve stems as required on a valve refacing machine using the " V e e " block attachment to insure a smooth 90° end. Also be certain to break sharp edge on ground valve tip. Observe an original valve to determine chamfer. After all valve keys have been installed on valves, tap each valve stem end with a hammer to seat valve retainers and keys. Using Gauge BT-6428 as shown in Fig. 6B-126 and Fig. 6B-127, re-gauge all valves between valve stem and gauge and valve retainer and gauge. If any valve stem end is less than .030" above retainer, the valve is too short and a new valve must be installed. EXAMPLE: Valve Retainer to Gauge Clearance Minus Valve Stem to Gauge Clearance This is less than .030" and a new valve should be installed.
VALVE GUIDE BORES

If a standard valve guide bore is being reamed, use the .003" or .005" oversize reamer. For the .010" oversize valve guide bore, use the .013" oversize reamer. If too large a reamer is used and the spiraling is removed, it is possible that the valve will not receive the proper lubrication. Occasionally a valve guide bore will be oversize as manufactured. These are marked on the inboard side of the cylinder heads on the machined surface just above the intake manifold surface, Fig. 6B-128. These markings are visible without removing any parts other than the air cleaner assembly. Before removing the cylinder heads to perform service to either the valves or valve guide bores, the cylinder heads should be inspected to determine if these markings are present. If no markings are present, the guide bores are standard. If oversize markings are present, any valve replacement will require an oversize valve. Service valves are available in five different stem diameters: Standard, .003" oversize, .005" oversize, .010" oversize, and .013" oversize.

.060" .035" .025"

REAMING PROCEDURE

Before attempting to ream the valve guide bores they should be cleaned using Tool BT-6415 as shown in Figure 6B-129. This procedure to ream valve guide bores using Tool BT-6414 is shown in Fig. 6B-130. Use care to hold reamer straight in valve guide bore.
REPLACING VALVE SPRING (HEAD O N ENGINE) (Fig. 6 B - 1 3 1 )

As previously stated, if the valve guide bores are worn excessively, they can be reamed oversize. The following reamers are available: BT-6414-1 .003" Oversize Valve Guide Reamer BT-6414-4 .005" Oversize Valve Guide Reamer BT-6414-3 .013" Oversize Valve Guide Reamer

To replace a worn or broken valve spring without removing the cylinder head proceed as follows:

6B-16

V-8 Engine

All Series

Fig. 6B-130

Reaming Valve Guide Bore

sible, then remove keys, spring retainer cups and springs. NOTE: If valve spring does not compress, tap tool with a hammer to break bind at retainer and keys.
Installation

Fig. 6B-128

Valve Guide Bore Marking

Removal

1. Remove rocker arm assemblies. 2. Remove spark plug and install Tool BT-721-B into spark plug hole and attach to an air hose to hold the valve against its seat. 3. Install Tool BT-6413, (Fig. 6B-132) compress the valve spring until valve keys are acces1. Install valve spring and spring retainer. Using Tool BT-6413 compress the valve spring until the valve keys can be installed. 2. Install spark plugs. Torque 35 ft. lbs. 3. Install rocker arm assemblies.

Fig. 6B-129

Cleaning Valve Guide Bores

Fig. 6B-131

Removing Valve Spring

Hoist the car and drain oil. 36 and 38 Series) Disconnect exhaust pipe from right exhaust manifold. 6 B . Remove the dip stick. Part No. Fig. on seal area and install pan. a. 4. b. 6. Removal 1. Wipe Lube. Torque 5/16" bolts to 15 ft. 3. Remove oil pan attaching bolts and remove oil pan. 6B-133 O i l Pan Installation . 3. Disconnect engine mounts and jack front of engine up as far as possible using Engine Support Tool BT-6501. 1 crankshaft throw up. Position No. Remove crossover pipe and starter. 1050169. (52 through 86 Series) Lower relay rod by disconnecting idler arm or pitman arm. Installation (Fig. in. 2.) 1. 5. (34. NOTE: Be sure distributor does not contact cowl and fan blades do not contact fan shroud.1 3 3 ) Fig.All Series V-8 Engine 6B-17 2. 6B-132 Valve Spring Tool OIL PAN ( 3 3 0 and 4 2 5 cu. Install front and rear seal (rubber). Apply 1050026 Sealer to both sides of pan gaskets (cork) and install on block.

DO NOT BOLT TOOL TO BLOCK since engine must rock when raised. 5. lbs. 6.) Refer to oil pan installation 330 and 425 cu. using the left engine mount as a pivot. 1 and No. 2 connecting rod journals should be at 4 or 7 o'clock position as viewed from front of engine. Removal 1. Remove Engine Support Bar Tool BT-6424-1 from rear of engine.6B-18 V-8 Engine All Series Fig. 4. NOTE: It is necessary to raise both the front and r e a r of the engine and tilt it to the left. 3. in. Position fork of tool to lift pulley hub. Use Tool BT-6501-3 to raise front of engine. 7. transmission crossmember. Remove oil pan attaching bolts and remove oil pan toward rear of engine. in. Disconnect "Neg" battery cable. 6B-134 Oil Pump Exploded View lbs. 2. OIL PAN ( 4 0 0 cu. Remove drive shaft. Installation ( 4 0 0 cu. Fill crankcase as explained in the PERIODIC MAINTENANCE Section. Remove upper radiator baffle. engines for gasket sealing and reverse the r e moval procedure.) NOTE: Remove the lower two right hand engine cover bolts to permit Tool BT-6501-3 to clear the water pump outlet. Raise right side of engine approximately 2-1/2" and insert block ToolJ-21662-1. NOTE: No. between upper and lower right hand mounts. Install Tool BT-6424-1 Engine Support Bar and insert a 1" block between tool and right rear corner of oil pan to obtain additional lift on right side. transmission and flywheel. 8. Disconnect left exhaust pipe and starter. and 1/4" bolts to 10 ft. 9. in. . Disconnect right hand engine mount.

6B-136 O i l Pump Installation OIL PUMP Removal valve to bore clearance is Assembly . Install the oil pan. cup. lbs. closed end first. as the spring is under pressure. If they are damaged. 3. Proper end clearance is . 6 B . Also check the pressure regulator valve. then remove pump and drive shaft extension. 3. Remove the cotter pin. Remove the drive gear and idler gear from the pump body. (Fig. Torque bolts to 35 ft. 1.1 3 4 ) 1. the END OF THE EXTENSION NEAREST THE WASHERS MUST BE INSERTED INTO THE DRIVE SHAFT. Inspection 1. lbs.0025" to .All Series V-8 Engine 6B-19 Fig.0025" to . 2. Installation Disassembly (Fig. head or heads. Remove the oil pump cover attaching screws and remove the oil pump cover and gasket. Insert the drive shaft extension through the opening in the main bearing cap and block until the shaft mates into the distributor drive gear. (Fig. to OIL PAN - Check the gears for scoring or other damage. 4. (Refer to OIL PAN- 2. Position pump onto the r e a r main bearing cap and install attaching bolts. the gear end clearance should be gauged. Remove intake manifold.0050". spring and the pressure regulator valve. then install the spring cup and retaining pin. Remove the oil pump to rear main bearing cap attaching screws. Install the drive gear into the pump with the hex ID of the drive shaft toward the oil pump mounting pad. 6B-135 O i l Pump Drive Shaft Extension Fig. Position a new gasket on the pump body and install the oil pump cover. Remove the oil pump drive shaft extension. Proper CONNECTING ROD AND PISTON ASSEMBLY Removal 1. Position the pressure regulator valve into the pump cover. Tighten the cover screws to 8 ft. 1. NOTE: Position thumb over pressure regulator bore before removing cotter pin. During assembly. . 2. new gears should be installed. The drive shaft extension and washers must be serviced as an assembly. 6B-136). 6B-135) 2. NOTE: When assembling the drive shaft extension to the drive shaft. 3. valve spring and bore for damage. R e m o v e Removal) oil pan. NOTE: Do not attempt to remove the washers from the drive shaft extension. then install the idler gear. Refer Installation.0065".

The connecting rod journals can be checked for out-of-round with the use of a micrometer. Adjustment for wear is compensated by replacing the bearing. If the journals are scored or ridged. Remove bearing cap and determine bearing clearances by comparing the width of the The connecting rod bearings are assembled with a slight projection above the rod and cap faces to insure a positive contact. 6B-137) 6.0015". connecting rod and outer and inner surface of bearing inserts. With connecting rod journal at the bottom. Slight roughness may be removed with a fine grit polishing cloth saturated with engine oil. Inspect journals for roughness and wear. 6B-138) 6. (Fig. This is to prevent damage to bearing journal and rod bolt threads. The right bank is numbered 2-4-6-8. If plastigauge is to be used: 5. NOTE: Stamp cylinder number on the machined surfaces of the bolt bosses of the connecting rod and cap for identification when reinstalling. Remove oil pan. 6B-137 Connecting Rod Bolt Guide Fig. lbs. ROD BEARINGS 1. 5. Remove oil pump assembly. Remove rod bearing cap and bearing. NOTE: Refer to ENGINE SPECIFICATIONS Chart at the back of this section. 7. Maximum out-of-round must not exceed . mark cylinder number on piston with a silver pencil or quick drying paint. 4. Burrs may be removed with a fine oil stone. Clean oil from journal bearing cap. left bank 1-3-5-7. Remove oil pan. NOTE: It may be necessary to remove oil pump to provide access to r e a r connecting rod bearings. then remove caps. Install guide hose over threads of rod bolts. 3. 2. Remove rod and piston assembly through the top of the cylinder bore. 3. 6B-138 Bearing Tang and Notch 2. remove ridge with ridge reamer before attempting to remove the piston and rod assembly. Remove other rod and piston assemblies in the same manner. Connecting rod bearings can be replaced without removing the rod and piston assembly from the engine. (Fig.6B-20 V-8 Engine All Series Fig. stamp cylinder number on machined surfaces of connecting rod and cap for identification when reinstalling. If the pistons are to be removed from the connecting rod. 7. 8. 4. Reinstall bearing cap and torque to 42 ft. Place a piece of plastigauge in the center of lower bearing shell. Position insert so that tang is properly aligned with notch in rod and cap. the crankshaft must be replaced. If ridge exists. Examine the cylinder bore above ring travel. .

9. PLASTIGAUGE. R O D ASSEMBLY If a rod is twisted or bent. 6B-140 Connecting Rod Side Clearance flattened plastigauge at its widest point with the graduation on the plastigauge container. Measure the rod side clearance as shown in Fig. 6B-140. a new rod must be Fig. All rods must be connected to their journals when rotating the crankshaft to prevent engine damage.All Series V-8 Engine 6B-21 . (Fig. Fig. The number within the graduation on the envelope indicates the clearance in thousandths of an inch. Repeat Steps 2 through 7 on remaining connecting rod bearings. 6B-141 Piston Identification . 6B-139 Checking O i l Clearance Fig.0035". NOTE: Lubricate bearing with SAE 10W30 oil before installation. FLATTENED . 6B-139) If this clearance is greater than . replace the bearing and recheck clearance with plastigauge.

the original cylinder size is stamped with a code letter on the block near each cylinder on the cylinder head surface. 6B-144 Piston Rings . When measuring taper. These pistons will be either . Insert piston with pin and rings removed. 3. The piston and cylinder bore must be free of oil and at the same temperature. slowly pull the scale in a straight line and note the reading on the scale. While holding the piston in the center of its normal travel. Place a strip of . 6B-143) Fig.001". 6B-142) NOTE: Refer to ENGINE SPECIFICATIONS Fig. measurement must be made on skirt 90° from piston pin hole (with the piston pin removed). 2. oversize pistons may be found. 6B-143 Checking Piston Clearance Fig. (Fig. at 90° to the normal piston pin location. 1. Attach Scale J-5515 to feeler gauge. (Fig. 6B-141) MEASURING PISTON NOTE: Refer to ENGINE SPECIFICATIONS Chart at the back of this section. The reading should be between 3 to 12 pounds while pulling the feeler gauge out of the bore.010" oversize. Allowable taper is . When replacing pistons.6B-22 V-8 Engine All Series When measuring piston for size or taper.005" or . CHECKING CYLINDER BORE PISTON (Fig. 6B-142 Cylinder Bore Marking installed. Each piston should be fitted to its individual cylinder and marked for that cylinder.0015" feeler gauge against the upper side of the bore. into bore with head downward. NO ATTEMPT SHOULD BE MADE TO STRAIGHTEN CONNECTING RODS. NOTE: On some c a r s . the largest reading must be at the bottom of the skirt.000" to .

055" for oil rings.010". It is important that the ring grooves be completely free of deposits.001" out-of-round and . Break sharp corners after filing. Ends of rings and rails must be filed square. refer to the instructions furnished with the parts package. 6 B . 6B-145 Measuring Piston Ring Gap Fig. 6 B . It is important that reconditioned cylinder bores be thoroughly washed with a soap and water solution to remove all traces of abrasive material to eliminate premature wear. The oil rings consist of two rails and an expander. ring gap and side clearance should be checked as follows: Piston Ring and Rail Gap Installation Each ring and rail gap must be measured with 1. Install connecting rod bolt guide hose over Fig. Each ring must be checked for side clearance (see chart) in its respective piston groove by inserting a feeler gauge between the ring and its upper land.015" to . CLEANING PISTON the ring or rail positioned squarely and at the bottom of the ring-travel area of the bore.001" taper. NOTE: To check oil ring side clearance.All Series V-8 Engine 6B-23 Chart at the back of this section. 6B-145) If the gap measurement is less than . Ring Tolerances RING IDENTIFICATION A N D INSTALLATION (Fig. the oil rings must be installed on the piston.0038" The pistons have three rings (two compression rings and one oil ring). (Fig. Deposits in the ring grooves should be removed with a suitable ring groove cleaning tool. minimum. ALLOWABLE SIDE CLEARANCE Oil Rings Compression Ring RINGS (Fig. Maximum allowable taper of the cylinder bore is .0051" 0018" to . The most wear will occur at the top of the ring travel.1 4 7 ) NOTE: For service ring specifications and detailed installation instructions. Cylinder bore size can be measured with inside micrometers or a cylinder gauge. file the ends of rings and rails until the minimum gap is obtained. 6B-146) The piston grooves must be cleaned before checking ring for side clearance. Reconditioned cylinder bores should be held to not more than .1 4 4 ) 0001" to .020" for compression rings and . (Fig. ROD A N D PISTON ASSEMBLY When installing new rings.010" to . Side Clearance Clean the pistons by scraping carbon off the top of the piston. 6B-146 Piston Ring Side Clearance .

when checked with a feeler gauge on each crankpin. the pin will not fall through. 6B-149) 3.002" to . If the clearance is . The pin is a press fit in the connecting rod. This will facilitate installation of remaining piston assemblies. If the pin to piston clearance is to the high limit (. lbs.0003" to .6B-24 V-8 Engine All Series Fig. ( F i g . with bearing index tang in rod and cap on same side. The clearance between the adjacent rods. Apply SAE 10W30 oil to rings and piston.0003". Torque rod bolt nuts to 42 ft. 6B-148) 2. 6B-150 Connecting Rod Side Clearance . Install assembly in its respective cylinder bore so notch cast in top of piston is towards the front of engine.011". 4. 6B-149 Piston Ring Compressor rod bolt threads.0005"). PISTON PINS The correct piston pin fit in the piston is . NOTE: When more than one rod and piston assembly is being installed. Lubricate the crankshaft journal with SAE 10W30 oil and install connecting rod bearing and cap. It is important that the piston pin hole be clean and free of oil when checking pin fit. (Fig. then install piston ring compressing tool on piston. (Fig. Fig. 6B-148 Connecting Rod Bolt Guides Fig. should be from . 6B-147 Piston Ring Identification Fig. 6B-150) 5. the connecting rod cap attaching nuts should only be tightened enough to keep each rod in position until all have been installed. the pin can be inserted in the piston with very little hand pressure and will fall through the piston by its own weight.0005" loose.

6B-151. and press pin out. use the following procedure. 6B-151 Removing Piston Pin Fig. 6B-153 Piston and Connecting Rod Assembly . Place Remover Tool BT-6408-3 in piston pin as shown in Fig. Fig. with the letter " F " on piston facing up. Place piston on piston pin remover Tool BT-6408-1. 2.All Series V-8 Engine 6B-25 Fig. Removal 1. 6B-152 Tool BT-6408 Whenever the replacement of a piston pin is necessary.

6B-152) 2. fan.0008" to . Install belt(s). Tool BT-6408-5. P r e s s in piston pin with Tool BT-6408-3 until it makes contact with Guide Stop Tool BT-6408-2 in Main Body Tool BT-6408-1. Install fan pulley and fan. 2. 2. (Fig. Adjust belts using Tool HARMONIC BALANCER NOTE: A harmonic balancer is used in place of the pulley hub on all except two barrel low compression 330 cu. BT-33-70M. 1. 3. 6B-153 for correct rod and piston assembly. lbs. Pin to connecting rod fit is . 6B-154. Remove belts. Install pulley. Place piston on Tool BT-6408-1 with letter " F " facing up. 6B-155 Removing Harmonic Balancer 1. fan pulley and crankshaft pulley.0016" tight. Installation 1. Place spring. engines. Removal Fig. Hoist car. Fig. Coat piston with SAE 10W30 oil. Refer to Fig. Place pin in piston as shown in Fig. This will automatically center the pin in the piston. 6B-154 Installing Piston Pin CRANKSHAFT PULLEY Removal Installation 1. 3. 6B-156 Installing Harmonic Balancer 3.6B-26 V-8 Engine All Series Fig. Remove belt(s) and fan. in. Remove four pulley bolts and pulley. Torque to 20 ft. and four bolts. . and Guide Stop Tool BT-6408-2 in main body Tool BT-6408-1.

Install pulley and belt(s). Part No. fan and fan pulley. and both radiator hoses. bypass hose. Use Tool 3. 3. 4.0007 loose. and pulley hub. Disconnect heater hose. Coat outside area of crankshaft pulley hub which enters seal with Special Seal Lubricant. timing pointer and water pump assembly. (Fig. Installation FRONT COVER 1. (Fig. 5. Drain cooling system. Fig. Using balancer puller. Remove washer. 6B-159 Front O i l Seal Installation pulley hub and to crankshaft key to prevent possible oil leakage. harmonic balancer hub bolt and NOTE: Balancer to crankshaft fit is . remove balancer as shown in Fig. Apply 1050026 Sealer to inside diameter of Removal 1. Install front cover. 1050169. Install new cover gasket. 2. Install harmonic balancer on crankshaft. 6B-158 Front O i l Seal Removal 2. 6B-155. Torque 160 ft. 3. 6B-157) Installation 1.All Series V-8 Engine 6B-27 Fig. 6B-157 Engine Front C o v e r Bolts 2. 4. 6B-156) F i g . crankshaft pulley. 2. Apply 1050026 sealer to gasket around water holes and place on block. timing pointer and water .001 tight to . Remove oil pan. Remove cover to block attaching bolts and remove cover. BT-33-70M and adjust. lbs. Remove all belts. Install washer and bolt.

lbs. 9. bypass hose and radiator hoses. Apply 1050026 Sealer to outside diameter of seal. 3. 4. crankshaft gear. 5. and adjust using Tool 1. remove oil seal shown in Fig. 7. Install and adjust belts. 4. 2. chain and cam gear. lbs. Torque 160 ft. Using Tool BT-6405. Remove the belts. Remove fuel pump eccentric. Apply SAE 10W30 oil to bolts (threads and heads) and install. Using Tool BT-6406. Installation 11. 3. Installation 1. Install fan pulley. 6B-161) 3. fan and four attaching bolts. install oil seal as shown in Fig. Install fuel pump eccentric with flat side rearward. Install oil slinger. Install crankshaft pulley and four attaching bolts. right valve cover.6B-28 V-8 Engine All Series pump assembly. 6B-160 Timing Gear Position Fig. 6B-159. 6B-161 Fuel Pump Eccentric . and align timing marks. Fill radiator and crankcase. 3. 6. Apply Lubricant 1050169 on pulley hub seal surface. 2. crankshaft gear and timing chain together. Remove oil slinger. 10. OIL SEAL Removal (Front Cover Installed) 1. Remove distributor cap. 1. 6B-158. 6B-160) 2. TIMING CHAIN AND GEARS (With Front Cover Removed) Removal 8. (Fig. Install b e l t s BT-33-70M. Install pulley hub and pulley hub bolt. Torque bolts evenly as indicated. Install camshaft gear. Remove the crankshaft pulley and pulley hub. 2. (Fig. lbs. Torque bolts to 20 ft. Install oil pan. Fig. Torque to 20 ft. Connect heater hose. as CHECKING VALVE T I M I N G WITHOUT REMOVING FRONT COVER 1. Install the pulley hub and crankshaft pulley.

4 piston will be at the top of the cylinder. Again measure from pivot boss surface to top of push rod. Installation NOTE: To insure proper camshaft installation Fig. push-rods and valve lifters. 4. Remove rocker arm assemblies. Slowly turn engine until rotor approaches No. See illustration for retarded and advanced dimensions. Remove intake manifold. 6B-162) 5. Remove oil slinger. Crank engine until rotor approaches No. (No. air conditioning condenser and front end sheet metal as necessary. 8. 4. 2. 4 spark plug wire position. 6B-162 Checking Valve Timing .¥ All Series V-8 Engine 6B-29 No. 6. No. Remove distributor. 1 spark plug wire position. Continue to turn engine until timing mark on crank pulley is aligned with 0 on indicator. Remove fuel pump. 4 intake valve) (Fig. 4 intake and exhaust rocker a r m s and pivot. 8. 6. 6B-163) Removal 1. No. This should be top dead center. 2. 6B-162) 7. Ground coil wire to engine. (Fig. timing chain and gears. CAMSHAFT (Fig. Remove front cover. Measurement should be approximately 3/16" more than the first measurement. 7. 3 Turn ignition switch on. Remove camshaft by carefully sliding it out the front of the engine. Measure from pivot boss on head surface to top of push rod. 1 piston will be at the top of the cylinder. 4 intake valve) Record measurement. 3. (No. Continue to turn engine until timing mark on crank pulley is aligned with 0 on indicator. 5. Remove radiator.

372 1. 582099. When installing the bearings. 1. IN.482 1.414 . 1.29400 . 330 CU.27080 .26745 . air conditioning condenser and front end sheet metal as necessary.24305 . 2BBL 1.27080 .426 1. Install intake manifold.26880 Q o 6 400 CU.362 1.472 . Install fuel pump. INTAKE EXHAUST CAM LIFT INTAKE EXHAUST 330 CU.416 1. 1. 4 and 5.28888 . then number 4. 6. The camshaft bearings must be replaced in complete sets.416 1.372 1.6B-3Q V-8 Engine All Series END VIEW OF CAMSHAFT ENGINE USAGE BASE CIRCLE DIA.372 1.28688 400 CU.29419 .388 1. & 1.29619 .29619 .424 1. number 5 must be installed first.29619 .414 .26880 Fig.26945 .T. 5. 3.426 1. Install valve lifters.426 1.-A.29419 . IN.29600 .362 . Install radiator. Number 1 bearing must be removed first. 4.M.24105 .378 . 3. IN. All bearings must be removed before any can be installed. Included with the available tools is Camshaft Bearing Remover and Installer Set BT-6409. IN. then 3. then number 2.-S.472 1. Install distributor. 2 and 1.26745 .362 1.414 . S. push-rods and rocker arm assemblies and valve covers. .26945 .26880 425 CU.424 1. AoT. CAMSHAFT BEARINGS 2. 1. Refer to ELECTRICAL Section. 6B-163 Camshaft Identification and to provide initial lubrication.24162 0 0 ^<-_—-^ 330 CUo IN 4BBL.27080 . IN. Install camshaft CAREFULLY. 7.M. it is important that whenever a camshaft is installed it must first be coated liberally with GM Concentrate. Part No.29419 425 CU. IN. 4BBL.416 1.24362 . (STARFIRE) 1.424 1. oil slinger and front cover.482 1. Install timing chain and gears.

3. 1. 2 Cam Bearing Tool BT-6409-2 on driver and drive out No. Mark top of bearing. Install No. 6B-164. place each bearing in the front bore with tapered edge toward block and align the oil hole in the bearing with the center of the oil slot in the bore. 1 Cam Bearing Remover and Installer BT-6409-1 on Handle J-8092 (existing tool) and drive out front cam bearing. 3. Remove BT-6409-5 Installer and install BT-6409-4. 6B-165) 2. Place No. Place new No. F i g . 2 bearing.All Series V-8 Engine 6B-31 2. 3 and No. 4 bearing on installer 1. Remove No. 4 bearings in the same manner. Installation Fig. When installing the bearings the mark will act as a guide. using BT-6409-3 and BT-6409-4 removers. NOTE: Each cam bearing is a different diameter and the correct sequence must be used both for removal and installation. proceed as follows: Removal (Camshaft Removed) NOTE: To aid in aligning bearings with oil passages. use Puller BT-6409-8 as shown in Fig. (Fig. To replace bearings with engine in car. To remove No. 6B-164 Removing Rear Cam Beari ng This set can be used to remove cam bearings with the engine either in or out of the car. 5 bearing with engine in chassis. Use BT-6409-9 to check oil hole opening as shown in Fig. 4. Place Pilot BT-6409-6 on Driver BT-6409-7 and i n s t a l l No. 6B-166. 6B-165 i n s t a l l i n g Rear Cam Bearing . 5 bearing on BT-6409-5 and drive bearing in until the last white line on the driver is flush with the front face of the pilot.

6B-167 Installing No. In. (Fig. 6B-166) Camshaft and Oil Galley Plugs (Fig. 5. 1 bearing on installer.6B-32 V-8 Engine All Series Fig. 6B-170 Fig. Wire must enter hole or the bearing will not receive sufficient lubrication. 6B-167) 6. Install Tool BT-6409-1 on Handle J-8092 and place No. 4. (Fig. The left hand r e a r oil galley plug is not shown. 2. 6B-166 Checking No. 6 B . . 3 and No. J Cam Bearing Installing Rear Main O i l Seal Upper Half 400 and 425 Cu. Use BT-6409-9 to check all oil hole openings. In. 5 O i l Hole and drive in until second to last white line on driver is flush with pilot. Drive bearing in until white line on Installer BT-6409-1 is flush with front face of block. Follow the same procedure to install No. 6B-169 Installing Rear Main O i l Seal Upper Half 330 Cu. 6B-168 Camshaft and O i l Gallery Plugs Fig. Fig.1 6 8 ) Fig.

All Series

V-8 Engine

6B-33

It is a threaded ; u S t forward of provided in the The cup plug threaded plug.

plug in the end of the left galley the distributor. A small hole is plug for distributor lubrication. shown provides access to the

6B-169 for 330 cubic inch engine or Fig. 6B-170 for 400 and 425 cubic inch engines) 4. After oil passages in crankshaft have been checked for being open and shaft is clean, place shaft in block. Lubricate thrust flanges of the center bearing with 1050169 Lubricant. Install caps with lower half of bearing lubricated with SAE 10W30 oil. Lubricate cap bolts with Part No. 1050125 and install, but do not tighten. 5. With a block of wood (Fig. 6B-171) bump shaft in each direction to align thrust flanges of center main bearing. 6. Torque Nos. 1, 2, 3 and 4 main bearing cap bolts to 80 ft. lbs. and No. 5 bolt to 120 ft. lbs. (330 cu. in. engine). Torque Nos. 1 through 5 to 120 ft. lbs. (400 and 425 cu. in. engines). 7. Reassemble engine and install in chassis.

The front oil galley plugs (not shown) are threaded. The plug on the right side has a small hole which provides lubrication for the timing chain and gears.

CRANKSHAFT
Removal

It is recommended that the crankshaft be r e placed with the engine out of the chassis. In order to remove the crankshaft, the oil pan, front cover, connecting rods, transmission and flywheel must be removed from the engine.
Installation

MAIN BEARINGS Main bearing clearance must not exceed .0035" on all bearings. The .0035" clearance is permissible only if the engine is disassembled for other than a bearing noise condition. If bearings are noisy or if a visual inspection indicates defective bearings, new bearings must be installed within the specifications outlined under MAIN BEARINGS - REPLACE. Bearings which fall within the .0035" specification should not be rejected if the bearings show a normal wear pattern or slight radial grooves, unless it has been established to be defective.
Checking Bearing Clearances

1. Measure the crankshaft journals with a micrometer to determine the correct size rod and main bearings to be used. NOTE: Whenever a new or reconditioned crankshaft is installed, new connecting rod bearings and main b e a r i n g s should be installed. 2. Position upper half of main bearings in block and lubricate with SAE 10W30 oil. 3. Install a new r e a r main bearing seal. (Fig.

1. Remove bearing cap and wipe oil from crank-

Fig. 6B-171

Aligning Center Main Bearing Flanges

Fig. 6B-172

Checking O i l Clearance

6B-34

V-8 Engine

All Series

attempted. NOTE: The upper and lower shells must be installed in pairs. Sizes of the bearings are i0> cated on the tang. (Fig. 6B-173) It is possible to have more than one bearing size in the same engine. To install main bearing follows: shells, proceed as

1. Remove bearing cap and remove lower shell. 2. Insert a flattened cotter pin or roll out pin in the oil passage hole in the crankshaft, then rotate the crankshaft in the direction opposite to cranking rotation. The pin will contact the upper shell and roll it out. 3. The main bearing journals should be checked for roughness and wear. Slight roughness may be removed with a fine grit polishing cloth saturated with SAE 10W30 oil. Burrs may be removed with a fine oil stone. If the journals are scored or ridged, the crankshaft must be replaced. NOTE: The journals can be measured for out-of-round with the crankshaft installed by using a crankshaft caliper and inside micrometer or a main bearing micrometer. The upper bearing shell must be removed when measuring the crankshaft journals. Maximum out-of-round of the crankshaft journals must not exceed .0015". 4. Clean crankshaft journals and bearing caps thoroughly b e f o r e installing new m a i n bearings. 5. Apply Special Lubricant, Part No. 1050169, to the thrust flanges of bearing shells on No. 3 bearing. 6. Place new upper shell on crankshaft journal with locating tang in correct position and rotate shaft to turn it into place using cotter pin or roll out pin as during removal. 7. Place new bearing shell in bearing cap. 8. No. 5 bearing - install new asbestos oil seal in the rear main bearing cap. (REAR MAIN BEARING OIL SEAL) (Fig. 6B-174 for 330 cubic inch engine or Fig. 6B-175 for 400 and 425 cubic inch engines) 9. Install bearing caps, lubricate bolt threads with Part No. 1050125 Lubricant and install. Torque Nos. 1 through 4 to 80 ft. lbs. and No. 5 to 120 ft. lbs. (330 cu. in. engine) Torque Nos. 1 through 5 to 120 ft. lbs. (400

Fig. 6B-173

Main Bearing Identification

shaft journal and outer and inner surfaces of bearing shell. 2. Place a piece of plastigauge in the center of bearing. 3. Use a floor jack or other means to hold crankshaft against upper bearing shell. This is necessary to obtain accurate clearance readings when using plastigauge. 4. Reinstall bearing cap and bearing. Place Part No. 1050125 Lubricant on cap bolts and install. Torque Nos. 1, 2, 3 and 4 bolts to 80 ft. lbs. and No. 5 bolt to 120 ft. lbs. (330 cu. in. engine). Torque Nos. 1 through 5 to 120 ft. lbs. (400 and 425 cu. in. engines). 5. Remove bearing cap and determine bearing clearance by comparing the width of the flattened plastigauge at its widest point with graduation on the plastigauge container. The number within the graduation on the envelope indicates the clearance in thousandths of an inch. (Fig. 6B-172) If this clearance is greater than .0035", REPLACE BOTH BEARING SHELLS AS A SET. Recheck clearance after replacing shells. (Refer to MAIN BEARINGS - REPLACE). NOTE: Main bearing end thrust clearance should be .004" to .008" as checked with a dial indicator.
M a i n Bearings—Replace

Main bearing clearances not within specifications (.0005" to .0021") must be corrected by the use of selective upper and lower shells. UNDER NO CIRCUMSTANCES should the use of shims behind the shells, to compensate for wear, be

All Series

V-8 Engine

6B-35

correcting engine r e a r main bearing upper seal leaks without the necessity of removing the crankshaft. The procedure for seal leak correction is listed below. 1. Drain oil and remove oil pan and rear main bearing cap. 2. Insert Packing Tool BT-6433 or BT-6434 against one end of seal in cylinder block and drive the old seal gently into the groove until it is packed tight. This varies from 1/4" to 3/4" depending on the amount of pack r e quired. (Fig. 6B-176) 3. Repeat this on the other end of the seal in the cylinder block. 4. Measure the amount the seal was driven up on one side; add 1/16", then cut this length from the old seal removed from the main bearing cap with a single edge razor blade. Measure the amount the seal was driven up on other side. Add 1/16" and cut another length from old seal. Use main bearing cap as a holding fixture when cutting seal as shown in Fig. 6B-177. 5. Place a drop of 1050026 Sealer on each end of seal. 6. Work these two pieces of seal into the cylinder block (one piece on each side) with two small screwdrivers. Using Packing Tool, pack these short pieces up into the block. Use Seal Trimming Tool BT-6436 to trim seal flush with block as shown in Fig. 6B-178. NOTE; Place a piece of shim stock between seal and crankshaft to protect bearing surface before trimming. 7. Form a new rope seal in the rear main bearing cap as outlined. 8. Assemble the cap to the block and torque to specifications.

Fig. 6B-174

installing Rear Main O i l Seal Lower Half - 330 Cu. In.

Fig. 6B-175

Installing Rear Main O i l Seal Lower Half400 and 425 Cu. In.

and 425 cu. in. engines)

REAR M A I N B E A R I N G UPPER O I L SEAL

Repair

Tools have been released to provide a means of

Fig. 6B-176

Packing O i l Seal

hammer seal into groove. 3. (Fig. Remove oil pan. Remove the r e a r main bearing cap. 2. 6B-177 C u t t i n g O f f Lower Seal Ends REAR M A I N LOWER OIL SEAL F i g . Remove r e a r seals. 6B-179 Rear M a i n Seal Repair Tools . Install seal into bearing cap. Clean bearing cap and seal grooves and inspect for cracks. packing by hand. Using seal installer. main bearing insert and old 1. Fig. 6B-178 C u t t i n g O f f Upper Seal Ends Removal 1. Installation 4.6B-36 V-8 Engine All Series Fig. 2. 6B-174 for 330 cubic inch engine or Fig.

the seal must be driven further into the seal groove. Install the new bearing. Install pan with new gaskets. (400 and 425 cu. 6B-180 Engine Layout . All old lubricant in the reservoir behind the bearing should be removed. Rotate tool before cutting off excess seal packing.6B-175 for 400 and 425 cubic inch engines) NOTE: To check if seal is fully seated in the bearing cap. 1050125 Lubricant and Torque Nos. away from edges. and No. remove with Pilot Bearing Puller BT-6619. 6B-181). Clean bearing insert and install in bearing cap. 7. in. cut seal flush with mating surface. FLYWHEEL One bolt hole in the flywheel is offset and it Fig. the seal is fully seated. Rotate seal installer when cutting seal to avoid damage to tool. lbs. 6 B . engines). lbs. lbs. 6B-182) STAKE BEARING (Fig. Install lower flywheel cover. PILOT BEARING (Manual Transmissioi On manual transmission equipped c a r s a pilot bearing is located in a bore in the rear end of the crankshaft. slide the tool away from seal. 1 through 4 to 80 ft. pack seal end fibers towards center. Clean crankshaft contact. 5. 1 through 5 to 120 ft. using Tool BT-6618 (Fig. With tool fully seated in the bearing cap. 8. lubricate bolt with Part No. bearing journal and seal threads install. 4. Torque Nos. 5 to 120 ft. When removing the pilot bearing. If undercut area of tool slides over the seal. (330 cu. engine). slide tool against the seal. 3. Install bearing caps. in. With tool slightly rotated. With screwdriver. (Fig. If tool butts against the seal.1 8 3 ) 6.

Drill two 3/16" holes in the gear and then split with a sharp chisel.6B-38 V-8 Engine All Series Fig. 6B-182 Installing Pilot Bearing Fig. Heat the new gear with a torch and place in Fig. 6B-184 Engine Support Tool . FLYWHEEL R I N G GEAR The flywheel ring gear may be replaced if damaged.BT-6501 . 6B-183 Staking Pilot Bearing Fig. 6B-181 Removing Pilot Bearing will attach to the crankshaft in only one position.

The pumps are serviced only as an assembly and can be identified by parts numbers stamped on the pump mounting base. All pumps have a sheet metal cover permanently sealed to the pump housing and cannot be disassembled for service.1 8 5 ) Five different fuel pumps will be used in 1966. FUEL PUMPS (Fig.All Series V-8 Engine 6B-39 sition o n t n e flywheel. it will become tight on the flywheel. Pump operating pressures for all V-8 fuel pumps will be 7-3/4 to 9 psi. Operating pressures for the L-6 engine are 4 to 5 psi without K-19 and 5-1/2 to 7 psi with K-19. Three on V-8 and two on the L-6. As the gear cools. 6B-185 Fuel Pump Identification . 6 B . Fig.

013" O.S. VALVE GUIDE REAMER J-5830-2 .S. MANIFOLD HEAT RISER BUSHING SET CRANKSHAFT PULLEY REMOVER PISTON PIN TOOLS PISTON PIN ADAPTER (L-6) VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR ADAPTER BT-6616 J-7583-3 BT-6610 BT-6601 J-5154 J-5830 CRANKSHAFT PULLEY REMOVER PILOT SCREW (USED WITH J-8614) CRANKSHAFT PULLEY AND GEAR REMOVER PLATE SCREW CRANKSHAFT TIMING GEAR AND FRONT OIL SEAL INSTALLER (L-6) J-5830-1 . 6B-186 Tools .030" O.S.S. VALVE GUIDE REAMER CAMSHAFT GEAR REMOVAL PLATE CAMSHAFT GEAR INSTALLER CAMSHAFT GEAR REMOVER VALVE ROCKER ARM STUD INSTALLER ROCKER ARM STUD REAMER . ROCKER ARM STUD REAMER .003" O.S.6B-40 V-8 Engine All Series * BT-6606 BT-6225 BT-6618 BT-6310 S-141 BT-6613 BT-6513 BT-6619 BT-6611 BT-6607 J-8614 BT-6408 BT-6614 BT-6413 BT-6612 ENGINE LIFT CHAIN COOL ING SYSTEM TESTER CLUTCH PILOT BEARING INSTALLER CARBURETOR FLOAT GAUGE CARBURETOR FUEL INLET NUT WRENCH ADAPTER FOR NEEDLE AND SEAT TESTER CARBURETOR NEEDLE AND SEAT CHECKER CLUTCH PILOT BEARING REMOVER CRANKSHAFT PULLEY INSTALLER (V-8) EXH. DISTRIBUTOR BUSHING INSTALLER DISTRIBUTOR BUSHING REMOVER FRONT COVER CENTERING GAUGE (L-6) CLUTCH PILOT BUSHING REMOVER (L-6) FRONT SEAL REMOVER PILOT FOR TOOL BT-6406 CAMSHAFT BEAR I NG SET J-22227 J-21795 J-8810 J-8880 J-5715 J-6036 J-9535 J-9534 J-21742 J-1448 BT-6406 J-9395 BT-6609 Fig.015" O.003" O. VALVE GUIDE REAMER J-5830-3 .

980" 1.880" 26.25:1 1-8-4-3-6-5-7-2 2.199"-1.Upper Lower No.687"-2.12388" 1.020" 0018"-.156"-1.055" 0001"-.0030" 002"-.620" 1.Oil Ring 90° V-Type 8 3. and 4 No.185" 1.195" 1.9385" x 3.136" 0003"-.4995"-2.201" 1. 1 No.0775" 010"-.3850" 330 Cu.Oil Holes in Crankshaft Clearance .2495"-2.0038" 1 015"-.0:1. of Cylinders Bore and Stroke (all) Piston Displacement (all) Compression Ratio Firing Order Main Bearing Bore (I.1248"-2.4985" 1.9791"-.Crankshaft End PISTON Diameter Nominal Outside Length Overall Top of Piston Pin to Center Clearance at Thrust Surface (selective) Weight Less Pin & Rings (all) Skirt Taper Ring Width (2 compression) (1 oil) PISTON PINS Diameter Length Overall Pin to Piston Clearance Pin to Rod Clearance PISTON RINGS No.0031" 970"-. 9.9795" 0015"-. .688" 2.670 oz. 5 CONNECTING RODS Length-Center to Center Diameter-Connecting Rod Bore Diameter-Pin Bore Bearing Clearance . 2 & 4 No.0005" Loose 0008"-.0016" Tight 2 0780"-.877"-1. 2 Bbl. 10. 3 No. . of Compression Rings (per piston) Width of Compression Rings (top & bottom) Gap Clearance Compression Rings Clearance in Groove Compression Rings . 5 Diameter-Connecting Rod Bearing Journal Width-Connecting Rod Bearing (with fillets) Length-Overall Crankshaft Diameter .872" 2.2500" . 0000"-.624" 5.008" 0015"-.193"-1.All Series V-8 Engine 6B-41 3 3 0 CUBIC INCH ENGINE SPECIFICATIONS CYLINDER BLOCK Engine Type No.Crankshaft End Thrust MAIN BEARINGS Oil Clearance-Crankshaft Vertical (all) Width-Bearing Shell No.D.0051" .9375" 3.0033" 0018"-. 1.0010" Larger at Bottom 0803" 1886" 9807"-. 3 No.Crankshaft (vertical) Side Clearance . 4 Bbl. 2.9803" 3.00125" 20. In. of Oil Rings (per piston) Gap Clearance.002" 2.) CRANKSHAFT Diameter-Main Bearing Journal (all) Width-Main Bearing Journal (with fillets) No.998"-6.116"-3.013" 3. Oil Ring Clearance in Groove .615" 00075"-.209" 004"-.470" 201"-.166" 1.

EXHAUST Diameter . 2.0050" Oil"-. 5 Width (including chamfers) No.9765" 1.0365" 2.041" 76-84 Lbs.870" 3425"-. 2 No.8427" 2.750" 48 500" .96" 192" 1.9573"-1.3427" 45° 037"-.0173"-2.0020" 410"-. 4 No.INTAKE Diameter .000" 0005"-.993" 500" 18 740"-.400" 1.9565" 810" 768" 775" 0012 M -.Stem Angle . 180-194 Lbs.) CAMSHAFT Bearing Journal Diameters No.3432" 45° 037"-. 1 No.0165" 1.567"-1.270" VALVE LIFTERS Diameter .Valve Seat Width . of Links Pitch 2.670" Load @ 1.3452" 1.0027" Hydraulic 1.Valve Seat Width .065"-1.Wire Inside Diameter Load @ 1. 3 No.075" 4. 1 No.740" 0010"-.077" 1.461" 410"-. of Teeth Overall Width of Gear CRANKSHAFT SPROCKET Width of Sprocket Overall Width of Gear Pitch No.400" 500" 36 471"-.6B-42 V-8 Engine All Series 3 3 0 CUBIC INCH ENGINE SPECIFICATIONS (Cont'd. 5 Journal Clearance in Bearing (all) End Thrust VALVE .Valve Seat Overall Length (all) Clearance in Guide Lash VALVE GUIDES Inside Diameter (intake & exhaust) VALVE SPRINGS Length Diameter .9773"-1.Head Diameter .Valve Seat Overall Length (all) Clearance in Guide Lash VALVE .9965" 1.557" 3420"-.Overall Clearance in Boss (selective) CAMSHAFT SPROCKET Width of Sprocket Pitch No.728" .9973"-1.886"-1. 3.Body Length .Stem Angle .0032" Hydraulic 3442"-.0373"-2. and 4 No.00"-.Head Diameter .0015"-. of Teeth TIMING CHAIN Width No. 8422"-.075" 4.

1 No. Oil Ring Clearance in Groove .156"-1.199"-1.0081" .6243"-2.0775" 013"-.877"-1. of Cylinders Bore and Stroke (all) Piston Displacement (all) Compression Ratio Firing Order Main Bearing Bore (I.136" 0003"-.996"-7.980" 1.Crankshaft End Thrust MAIN BEARINGS Oil Clearance-Crankshaft Vertical 1. 2. 3 No.975" 400 Cu.Oil Ring 90° V-Type 8 4.008" 0015"-.195" 1. .4988" 1.0018"-. In.013" 4" 3.624" 6. 2.0018" 002"-.0033" . of Compression Rings (per piston) Width of Compression Rings (top & bottom) Gap Clearance Compression Rings Clearance in Groove Compression Rings .189" 3.055" 0021"-.Crankshaft (vertical) Side Clearance .0000"-.000" 2.25:1 1-8-4-3-6-5-7-2 3.615" 00075"-.0034" 970"-.470" 201 "-.166" 1.) CRANKSHAFT Diameter-Main Bearing Journal (all) Width-Main Bearing Journal (with fillets) No. 5 Diameter-Connecting Rod Bearing Journal Width-Connecting Rod Bearing (with fillets) Length-Overall Crankshaft Diameter .0038" 1 015"-.116"-3.6250" 9791"-. 5 CONNECTING RODS Length-Center to Center Diameter-Connecting Rod Bore Diameter-Pin Bore Bearing Clearance .00125" 23.460 Oz.All Series V-8 Engine 6B-43 400 CUBIC INCH ENGINE SPECIFICATIONS CYLINDER BLOCK Engine Type No.9795" 0008"-.0003"-2. 3 & 4 5 Width-Bearing Shell No. .Upper Lower No.620" 1.9807" 3.0005" Loose 0008"-.185" 1.9993" 1.D. 3 No.126" x 3. 0031" 0020" -.209" 004"-.0016" Tight 2 0780"-.872" 2. 10.201" 1. 1. of Oil Rings (per piston) Gap Clearance. and 4 No.Oil Holes in Crankshaft Clearance .Crankshaft End PISTON Diameter Nominal Outside Length Overall Top of Piston Pin to Center Clearance at Thrust Surface (selective) Weight Less Pin & Rings (all) Skirt Taper Ring Width (2 compression) (1 oil) PISTON PINS Diameter Length Overall Pin to Piston Clearance Pin to Rod Clearance PISTON RINGS No.193"-1.188"-3.880" 26.5003"-2. 2 & 4 No.023" 0018"-.0010" Larger at Bottom 0803" 1886" 9803"-.

5 Width (including chamfers) No.063" 4.Wire Inside Diameter Load @ 1.0373"-2.587" 001" to .9565" 810" 768" 775" 0012"-.Body Length . 1 No.003" Hydraulic 3442"-.9765" 1.3427" 45° 037"-.9965" 1. 9210"~.629"-1.Valve Seat Width .052" 3425"-.Head Diameter .075" 4.9573"-1.Valve Seat Overall Length Starfire Clearance in Guide Lash VALVE .Stem Angle . and 4 No.) CAMSHAFT Bearing Journal Diameters No.844"-Linkbelt 48 500" .619" 3420"-.993" 500" 18 875"-Morse. 1 No.96" 192" 1.521" 500" 36 471"-.593" 001" to .041" 76-84 Lbs.Head Diameter .062"-2.003" Hydraulic 1. of Teeth TIMING CHAIN Width No. 180-194 Lbs. 2 No.1073"-2.Valve Seat Width . of Teeth Overall Width of Gear Hub CRANKSHAFT SPROCKET Width of Sprocket Overall Width of Gear Pitch No.0050" 011"-.9773"-1.3452" 1.270" VALVE LIFTERS Diameter .520" 1.9973"-1.0165" 1. .0365" 2. 3. 4 No.461" 530"-.INTAKE Diameter .125" 0005"-. 5 Journal Clearance in Bearing (all) End Thrust VALVE .001"-. 2. of Links Pitch 2.Overall Clearance in Boss (selective) CAMSHAFT SPROCKET Width of Sprocket Pitch No.6B-44 V-8 Engine All Series 4 0 0 CUBIC INCH ENGINE SPECIFICATIONS (Cont'd.077" 2.3432" 30° 030"-.0020" 529"-.065"-1.Valve Seat Overall Length Clearance in Guide Lash VALVE GUIDES Inside Diameter (intake & exhaust) VALVE SPRINGS Length Diameter .Stem Angle .670" Load @ 1.9215" 2.EXHAUST Diameter . 3 No.

615" 00075"-.9993" 1. 2.975" 425 Cu. 3 No. 0000"-.872" 2.0010" Larger at Bottom 0803" 1886" 9803"-.880" 26. 1.0038" 1 015"-.470" 201 "-.624" 6.) CRANKSHAFT Diameter-Main Bearing Journal (all) Width-Main Bearing Journal (with fillets) No. 3 No.00125" 23.156"-1.5003"-2.996"-7.193"-1.460 Oz.008" 0015"-.620" 1. 2 & 4 No. Oil Ring Clearance in Groove .166" 1.000" 2.185" 1.209" 004"-.125" 3. of Cylinders Bore and Stroke (all) Piston Displacement (all) Compression Ratio Firing Order Main Bearing Bore (I.188"-3. 1 No.Crankshaft End PISTON Diameter Nominal Outside Length Overall Top of Piston Pin to Center Clearance at Thrust Surface (selective) Weight Less Pin & Rings (all) Skirt Taper Ring Width (2 compression) .055" 0021"-.0081" .Oil Ring 90° V-Type 8 4.9795" 0008"-.0031" 0020"-.0034" 970"-.0775" 013"-.189" 3.Crankshaft End Thrust MAIN BEARINGS Oil Clearance-Crankshaft Vertical 1.9807" 3. See Engine Ident. 2. .023" 0018"-.Oil Holes in Crankshaft Clearance .0003"-2.4988" 1.0018" 002"-. (1 oil) PISTON PINS Diameter Length Overall Pin to Piston Clearance Pin to Rod Clearance PISTON RINGS No.6250" 9791"-. In.6243"-2.013" 4. Chart Section "O and OE" 1-8-4-3-6-5-7-2 3. 5 Diameter-Connecting Rod Bearing Journal Width-Connecting Rod Bearing (with fillets) Length-Overall Crankshaft Diameter .126" x 3.Crankshaft (vertical) Side Clearance .195" 1.All Series V-8 Engine 6B-45 4 2 5 CUBIC INCH 54 THROUGH 86 SERIES ENGINE SPECIFICATIONS CYLINDER BLOCK Engine Type No.201" 1.0033" 0018"-.136" 0003"-.980" 1. 5 CONNECTING RODS Length-Center to Center Diameter-Connecting Rod Bore Diameter-Pin Bore Bearing Clearance . and 4 No.Upper Lower No. . of Compression Rings (per piston) Width of Compression Rings (top & bottom) Gap Clearance Compression Rings Clearance in Groove Compression Rings . 3 & 4 5 Width-Bearing Shell No.116"-3.0005" Loose 0008"-.D. of Oil Rings (per piston) Gap Clearance.877"-1.199"-1.0016" Tight 2 0780"-.

Valve Seat Width .670" Load @ 1. of Teeth Overall Width of Gear Hub CRANKSHAFT SPROCKET Width of Sprocket Overall Width of Gear Pitch No.619" 3420"-.Wire Inside Diameter Load @ 1. 180-194 Lbs.9215" 2.Head Diameter . 3 No.3427" 45° 037"-.EXHAUST Diameter .003" Hydraulic 3442"-.Valve Seat Width . 1 No.9973"-1.125" 0005"-.629"-1.96" 192" 1.041" 76-84 Lbs.3425"-.587" 4.) CAMSHAFT Bearing Journal Diameters No.9773"-1.INTAKE Diameter . 2.0365" 2.075" 4.Valve Seat Overall Length Starfire Overall Length (except Starfire) Clearance in Guide Lash VALVE GUIDES Inside Diameter (intake & exhaust) VALVE SPRINGS Length Diameter .Body Length .Head Diameter .Stem Angle .000"-1.521" 500" 36 471"-.Stem Angle .Valve Seat Overall Length Starfire Overall Length (except Starfire) Clearance in Guide Lash VALVE .003" Hydraulic 1.557" 001"-.3452" 1. 844"-Linkbelt 48 500" .9573"-1.063" 4. 1 No.001"-. 5 Journal Clearance in Bearing (all) End Thrust VALVE . 4 No.0050" 011"-.270" VALVE LIFTERS Diameter .9965" 1.563" 001"-.065"-1.461" 530"-. 5 Width (including chamfers) No.077" 2. of Teeth TIMING CHAIN Width No. 3.0020" 529"-.993" 500" 18 875"-Morse.6B-46 V-8 Engine All Series 425 CUBIC INCH 54 THROUGH 86 SERIES ENGINE SPECIFICATIONS (Cont'd.9565" 810" 768" 775" 0012"-.520" 1. 9210"-.0373"-2.1073"-2.0165" 1. 2 No.593" 4.3432" 30° 030 n -.990" . and 4 No.9765" 1.Overall Clearance in Boss (selective) CAMSHAFT SPROCKET Width of Sprocket Pitch No. of Links Pitch 2.

5 Qts.0050" 0025"-. Application FUEL PUMP Fuel Pump to Block Bolt and Nut Fuel Pump Eccentric to Camshaft EXHAUST SYSTEM 25 65 15-20 120 80 120 80 42 35 8 35 25 7 15 8 50 50 20 35 35 25 20 20 13 20 35 8 25 15 15 5 50 35 25 15 14 35 15 ENGINE Crankshaft Bearing Cap Bolts (400 cu. in. 2.Gear 166 9 4 Qts.8 ENGINES) FLYWHEEL No. and 425 cu. . engine) •Cylinder Head to Block Connecting Rod Nuts Oil Pump to Bearing Cap Bolts Oil Pump Cover to Pump Bolts Rocker Arm Studs to Head Rocker Arm Nuts to Studs Valve Cover Bolts Oil Pan Bolts 5/16" Oil Pan Bolts 1/4" Oil Pan Drain Plug Crankshaft Balancer or Hub to Crankshaft Bolt Oil Filter Element to Base Oil Filter Assembly to Cylinder Block Bolts Front Cover to Cylinder Block Bolts 3/8" Front Cover to Cylinder Block Bolts 5/16" Fan Driven Pulley to Hub Bolts Fan Driving Pulley to Hub or Balancer Bolts Water Pump to Front Cover Bolts Water Outlet to Manifold Bolts *Intake Manifold to Cylinder Head Bolts Intake Manifold Baffle to Cylinder Block Bolts Exhaust Manifold to Cylinder Head Bolts Carburetor to Intake Manifold Bolts Tube and Plate to Intake Manifold Bolts Air Cleaner to Carburetor Stud Motor Mount to Cylinder Block Bolts Starter to Cylinder Block Bolts Starter Brace to Cylinder Block Bolt Starter Brace to Starter Bolt Distributor Clamp to Cylinder Block Bolt Spark Plugs Coil to Intake Manifold Bolt •Clean and dip entire bolt in engine oil before tightening to avoid an erroneous torque reading. engines) Crankshaft Bearing Cap Bolts Nos. in. Lbs. of Teeth on Starter Pinion LUBRICATION SYSTEM Crankcase Capacity Drain and Refill Drain & Refill with Filter Change Oil Pump Clearance P r e s s u r e Relief Valve in Bore End Clearance . Checking of torque during inspection may be 10% below specification. in. Ft. 5 (330 cu. in. of Teeth on Starter Gear No. engine) Crankshaft Bearing Cap No.0065" TORQUE SPECIFICATIONS NOTE: Specified torque is for installation of parts only. 3 & 4 (330 cu. 1. 0025"-.All Series V-8 Engine 6B-47 ENGINE SPECIFICATIONS (ALL V .

6B-48 V-8 Engine All Series For Torque Requirements on Generator. Refer to Table Below: Bolt Size 5/16" 3/8" 7/16" Torque 25 35 50 . Power Steering and Compressor Mounting Brackets.

Cars equipped with K-19 Air Injection Reactor System require no special maintenance or procedure recommendations other than an annual tune-up and air pump belt inspection and adjustment. 4. check for excessive burning or pitting.V-8 IGNITION SYSTEM DIAGNOSIS TUNE-UP CHART DISTRIBUTOR TEST SPECS 6C-4 6C-4 6C-5 6C-6 6C-9 6C-9 ENGINE TUNE-UP To maintain the most satisfactory engine performance. Refer to Idle Speed Chart in this section for specifications.8 ENGINE) Fig. lbs. (Fig. Remove foreign material from around the 1. . (Fig. 6C-2) DWELL ANGLE ( V . it is recommended that the following items be performed every 12. Do not attempt to remove all roughness. Adjust spark plug gap to . using a feeler gauge or dial indicator.All Series Engine Tune-Up 6C-1 ENGINE TUNE-UP (ALL SERIES) CONTENTS OF SECTION 6C Subject Page Subject Page ENGINE TUNE-UP 6C-1 SPARK PLUGS 6C-1 DISTRIBUTOR CONTACT POINTS . 2.030" using a round feeler gauge. . Install plugs using new gaskets and torque 35 ft. Calibrate dwell meter to set line and connect one lead of dwell meter to the primary . 3. Apply a film of cam and ball bearing lubricant or equivalent to the breaker cam. Remove scale from points with a fine cut contact point file. 6C-1) Do not file center electrode on new plugs. Rotate engine until breaker arm rubbing block is on high point of lobe.L-6 6C-3 CYLINDER HEAD TORQUE AND VALVE ADJUSTMENT COMPRESSION TEST ON-CAR ADJUSTMENTS . SPARK PLUGS spark plug holes and remove the spark plugs. Replace if necessary. 2. Inspect points. 5. Clean all serviceable plugs with an abrasive type cleaner. Adjust distributor contact point gap to . 2. All other specifications are the same as for c a r s without K-19.019" (new points) or . idle mixture. Clean exterior of plugs and inspect for cracked insulators or excessively burned electrodes. Contact Point Adjustment (L-6 Engine) 1. 6C-1 Filing Center Electrode 1.6C-1 DWELL ANGLE 6C-1 IGNITION TIMING 6C-2 SLOW IDLE ADJUSTMENT 6C-2 ON-CAR ADJUSTMENTS . slow and fast idle speed. File center electrode flat. check the timing. .000 miles: Service the spark plugs and ignition points.016" (used points). DISTRIBUTOR CONTACT POINTS 1. 3.

2. NOTE: The L-6 timing pointer is marked in 2° increments. proceed as follows: 1. insert Dwell Adjusting Tool J-6296 or BT-1501 through distributor window into the head of the adjusting screw. The " O " marking is TDC and all BTDC settings are on the " A " (advance) side of " O " . Remove tape and connect distributor vacuum advance line. adjust slow idle as outlined in chart. 6C-2 Contact Point Adjustment (L-6 Engine) Adjusting Dwell Angle (V-8 Engine) distributor lead terminal (negative (-) terminal of coil) and the other lead to ground. IGNITION T I M I N G excessive carbon build-up in the combustion chamber. A saw slot on the balancer indicates engine top dead center. the timing may be advanced beyond the specified setting providing spark knock is not encountered. In areas that have an extra high octane. Adjust engine speed to 850 rpm. 6C-3 Fig. Disconnect distributor vacuum line at carburetor and cover fitting with tape. 6C-4) To adjust ignition timing. NOTE: If a tuned engine detonates with this setting. the cause is low octane fuel or With the engine at normal operating temperature and air cleaner removed. 6C-3) Adjust dwell angle to 30°. the timing should be retarded 2-1/2° from the specified settings. Fig. 6C-4 Timing Marks . With the use of a timing line set timing according to chart. To adjust the ignition timing loosen the distributor clamp bolt and rotate the distributor. (500 rpm on L-6) 3. With engine running at idle speed. If these factors are not corrected. (Fig. Tighten the distributor clamp bolt and recheck timing to make sure distributor was not moved during tightening of bolt.6C-2 Engine Tune-Up All Series Fig. (Fig. SLOW IDLE ADJUSTMENT The ignition timing marks are located on the engine front cover. 5. 4.

All Series Engine Tune-Up 6C-3 Fig. 6C-5 On-Car Adjustments (L-6 Engine) .

NOTE: If equipped with G67. The actual temperature of the oil is not as important as stabilizing the oil temperature. Valve lash must always be adjusted after the head has been torqued. 3 and 4 to adjust the rest of the valves. 6. back off valve rocker arm nut until the valve rocker arm starts to clatter. remove rocker arm covers and gaskets. NOTE: This 1 turn preload adjustment must be done slowly to allow the lifter to adjust itself to prevent the possibility of interference. do not reduce idle speed setting since the idle compensator is open. In this position. When checking cylinder compression. and no cylinder reading should be less than 100 pounds. To determine if the valves or pistons are at fault. 3. This is normally accompanied by a higher manifold vacuum reading and/or an increase in idle rpm. Before adjusting the valve stem to rocker arm clearance. and torque bolts to specifications. 4. This is very important because during the warm-up period.005" from a cold check through the normalizing range. the ignition system primary is grounded in the ignition switch. the valve clearances will change considerably. the throttle and choke should be open. a test should be made to determine the cylinder compression pressure. With the engine running at idle. cylinder head and cylinder block are relative to this oil temperature. until nut has been turned down 1 full turn from the zero lash position. push rods. readjust to correct rpm. Then turn out each needle 1/4 turn. The lowest reading cylinder should not be less than 80% of the highest. only after the oil temperature is stabilized. Tests have shown that valve clearances will vary as much as . Repeat Steps 2. NOTE: It may be necessary to readjust idle speed and mixture after air cleaner is installed on car. If idle speed decreases. make sure the idle compensator is closed by holding it down with a pencil or other suitable tool. Clean gasket surfaces on cylinder heads and rocker arm covers with degreaser then install rocker arm covers. Covering the radiator will not materially hasten this normalizing process because even with the water temperature quickly raised.6C-4 Engine Tune-Up All Series After the idle rpm is stabilized. which might result in internal damage and/or bent push rods. With this system. between the inlet valve head and top of piston. The expansion or contraction of the valves. Turn rocker arm nut down slowly until the clatter just stops. When setting idle speed and mixture on carburetors with an idle compensator (factory installed air conditioning only). Energizing the starter will cause damage to the ground contact in the ignition switch and to the ignition contact in the starter solenoid. Adjusting the valves during or before this warm-up period will produce clearances which will be far from correct after the engine reaches normal operating temperature. all spark plugs removed. do these parts stop expanding and valve clearance changes cease to take place. Turn nut down 1/4 additional turn and pause 10 seconds until engine runs smoothly. Repeat additional 1/4 turns. or a leak is suspected. CYLINDER HEAD TORQUE A N D VALVE ADJUSTMENT (L-6 ONLY) PROCEDURE 1. the starter must not be energized when the ignition switch is in the "off" position. This is the zero lash position. . If the idle speed increases when the air cleaner is installed. vacuum pump must not be operating. using new gaskets. consequently the engine should be run 15-20 minutes to properly normalize all parts. pausing 10 seconds each time. NOTE: The ignition resistor is by-passed during cranking through a contact in the starter instead of through a contact in the ignition switch. Therefore. and the battery at or near full charge. Tool BT-1501 can be used to turn idle mixture adjusting screws. COMPRESSION TEST Retorquing the cylinder head bolts is not necessary unless a gasket has been replaced. 5. Gaskets adhearing to cylinder head and rocker arm cover may be sheared by bumping end of rocker arm cover rearward with palm of hand or a rubber mallet. NOTE: Do not pry rocker arm cover loose. Noisy lifters should be replaced. turn in or out each idle adjusting screw until the smoothest possible idle is obtained. it is extremely important that the engine be thoroughly warmed up to normalize the expansion of all parts. at which time both vacuum and idle rpm will drop off slightly. 2. it does not change the rate at which the oil temperature increases or the engine parts become normalized. After the engine has been normalized.

All Series Engine Tune-Up 6C-5 Fig. 6C-6 On-Car Adfusfmenfs (V-8 Engine) .

16.Compression low on first stroke tends to build up on following strokes but does not reach normal. 11. Retarded valve timing. 7. 17. Stuck power valve or piston. 2. 8. Transmission slipping. 5.Low on first stroke does not tend to build up on following strokes. 13. Vapor lock.6C-6 Engine Tune-Up All Series Valves . 9. Excessive carbon in heads. Distributor points or incorrect dwell and ignition timing. 6C-7 Accelerator Pedal (L-6 Engine) Normal _ Compression builds up quickly and evenly to specified compression on each cylinder. 14. Plugged carburetor air cleaner. Insufficient vacuum advance. 6C-8 Throttle Linkage . Restricted high speed jets. 20. Spark plugs fouled. Stuck heat r i s e r valve. 12. 6. Lack of fuel at carburetor. 3. Low fuel pump pressure. IGNITION SYSTEM DIAGNOSIS HIGH SPEED PERFORMANCE Fig. . incorrect gap or heat range. 15. Burned or sticky valves. 4. Piston Rings 1. Restricted exhaust system. Does not improve much with addition of oil.L-<6 Engine . Fig. Closed or partially closed choke. Worn or seized piston rings. 19. I m p r o v e s considerably with addition of oil. High engine oil pump pressure. Foreign material or water in fuel. low floats. weak or broken springs. 10. Weak or shorted coil or condenser. 18.

6C-10 Throttle Linkage (34. 36 and 38 Series) .All Series Engine Tune-Up 6C-7 Fig. 6C-9 Throttle Linkage (52 through 86 Series) Fig.

Lack of fuel at carburetor. Hydrostatic lockup. HARD START HOT 1. 14. Distributor points burned or misadjusted. 12. Ignition switch problems. 5. 13. High or misaligned floats. Distributor points burned. 4. 5. 18. Transmission slipping or high shifts. shows rich gas mixture. Spark plugs fouled. Low engine vacuum. 8. Misadjusted transmission stator switch. 12. Spark plugs fouled. 2. Flooding condition. ENGINE W O N ' T CRANK 7. Incorrect axle ratio. Battery cables loose or corroded. Closed choke. Starter drawing excessive amperage. Flooding condition. Discrepancy while flow meter testing and driver's habits. 1. 4. Weak or shorted coil. 3. Distributor points misadjusted or burned or shorted condenser. . 8. 10. Ignition switch problems. Closed or partially closed choke. Weak or shorted coil. Battery cables loose or corroded. Vapor lock. 6. Spark plug or distributor wires loose or shorted. 2. 13. Low battery. 15. Remove spark plugs to look for water or gasoline in cylinders. Weak or shorted coil. Loose coil or ignition wires. Starter drawing excessive amperage. 2. Stuck power piston or wrong size in m e tering jets. Carburetor or atmospheric vent closed. Plugged positive crankcase ventilation system. 10. Loose coil or ignition wires. 10. 2. Defective starter motor. 7. 17. 3. Distributor points burned or misadjusted. Plugged carburetor air cleaner. 15. 11. High fuel pump pressure. Foreign material or water in fuel system. 12. 19. weak or broken springs. 4. Spark plugs fouled or cracked. Lack of fuel at carburetor. Plugged idle jets or improperly adjusted idle screws. 8. 6. 13. Shorted distributor condenser. 3. 14. 7. 14. 5. no spark at plugs. Stuck heat r i s e r valve. Carburetor dechoker misadjusted. Seized engine. Stuck heat riser valve. 3. Choke stuck open. HARD START COLD GAS MILEAGE 1. 8. Retarded or advanced valve timing. 2. Weak or shorted coil. Low battery and loose or corroded cables. Low compression. 10. Spark plugs fouled. Vacuum leak. 4„ 5. Incorrect air fuel ratio at 1500 rpm test. 7. Misadjusted or defective neutral safety switch. 9. 11. Plugged positive crankcase ventilation system. 16. Carburetor icing. Low compression. Low tire pressure. Turn crank pulley with socket and ratchet. Stuck heat riser valve. 14. Brake drag. IDLE—MISSES OR ROUGH 1. Incorrect dwell and ignition timing. Low compression. 6. 6. 5. High fuel pump pressure. 9. 6. Burned or sticky valves. 9. 1. Low battery. 6. 5. 13. Black smoke at tail pipe. 7. 4. 4. Leaky head gaskets.6C-8 Engine Tune-Up All Series ENGINE WILL CRANK BUT W O N ' T START 1. 11. 11. 12. Starter drawing excessive amperage. Low battery. 3. 2. Plugged carburetor air cleaner. 9. Distributor points burned or misadjusted. Worn cam lobe. 3. Wrong speedometer gear.

.C. In. **Refer to Engine Identification Chart. Hg. . 330 L. .019" Set Choke * * * * * * * * 7. In. 1111042 1116232 H.C. In.) 425 Cu. 1111048 1116232 9° 15-1/2 to 19-1/2 In. . 1111151 1115361 9° 16-1/2 to 18-1/2 In.) 330 Cu. 1111089 1116232 9° 15-1/2 to 19-1/2 In. Start 6 to 8 In. Hg.C. 400 425 Start 6 to 8 In. 4 Bbl. In.L.5° (850 RPM) 5° (850 RPM) 7.(2 Bbl.C.H. 400 RPM 0° to 2° 7-3/4° to 9-3/4° 1025 RPM 2000 RPM 14° to 16° 400 RPM 0° to 2° 7-1/2° to 9-1/2° 1000 RPM 2125 RPM 12° to 14° 0° to 2° 6° to 8° 10° to 12° 400 RPM 900 RPM 2000 RPM All Start 6 to 8 In. Charts.5° (850 RPM) 7. In. . Hg.(2 Bbl.(4 Bbl.030" .(4 Bbl. Hg. .5° (850 RPM) 7. . Spec.) 400 Cu.) 425 Cu.(2 Bbl.(2 Bbl. . 2 Bbl.H. In. Hg.All Series Engine Tune-Up 6C-9 ENGINE TUNE-UP CHART Set Timing (Vacuum Disconnected) 6° (500 RPM) **Engine Usage 250 Cu. 1111029 1116232 9° 15-1/2 to 19-1/2 In.C.L.H.(4 Bbl.) 330 Cu. Hg.H.C. .035" . .) 425 Cu. BASED ON DISTRIBUTOR RPM Vacuum Advance Per Inch Of Vacuum 5 to 7 In.) Spark Plugs 46N 45S 44S 44S 44S 45S 44S 44S Plug Gap . In.5° (850 RPM) *For choke settings refer to Carb. Hg.5° (850 RPM) 7. Carb. In.) 330 Cu. DISTRIBUTOR TEST SPECIFICATIONS ENGINE Cu. Start 6 to 8 In. * Refer to Engine Identification chart.030" . In.5° (850 RPM) 7. Ratio DISTRIBUTOR Part No. . .C. . H. 425 600 RPM 0° to 2° 3-1/2° to 5-1/2° 900 RPM 2100 RPM 8° to 10° 0° to 2° 13° to 15° 400 RPM 2000 RPM 425 * Engine options L74 and L76 use the same distributor. Vacuum Unit No. **Comp. Hg.C. Hg.030" . 14-1/2 In. Hg. 9° 15-1/2 to 19-1/2 In. Section 6M. Hg.C. Hg. Mechanical Advance Per Distributor RPM 0° 2-1/2° 6-1/2° 13° to to to to 500 2° 4-1/2° 600 8-1/2° 800 1400 15° RPM RPM RPM RPM (L-6) 250 All Start 1110351 1116235 10° *H.030" Set Dwell 31°-34° 30° 30° 30° 30° 30° 30° 30° Breaker Gap .030" .L-6 (1 Bbl. . .C.C.030" . L.030" . Start 8 to 10 In. Adj. Carb.

6C-10 Engine Tune-Up All Series .

Engine Cooling 6K-1 ENGINE COOLING SYSTEM ALL ENGINES CONTENTS OF SECTION 6K Subject ENGINE COOLING SYSTEM COOLING SYSTEM . through the radiator core and lower tank to the water pump inlet where the cycle is repeated. Thus both the fan and pump are belt driven by a crankshaft pulley bolted to the harmonic . The pressure valve is held against its seat by a spring of predetermined strength which protects the radiator by relieving the pressure if the pressure should exceed that for which the radiator is designed. During cold engine operation when the thermostat is closed. COOLING SYSTEM CIRCULATION V . The bearings are permanently lubricated during manufacture and sealed to prevent loss of lubricant and entry of dirt. 6K-1 Pressure Radiator C a p The pressure type radiator filler cap contains a blow off or pressure valve and a vacuum or atmospheric valve. the coolant flows up through openings to the r e a r of the cylinder bank into the cylinder heads. At the forward end of the cylinder heads the coolant flows into the intake manifold. After flowing the full length of the cylinder banks. FAN BLADE IDENT. A nipple in the manifold allows connection of the heater hose. The coolant flows forward in the cylinder heads to cool the combustion chamber areas.L-6 FAN WATER PUMP ENGINE COOLING SYSTEM The engine cooling system is the pressure type with thermostatic control of coolant circulation. A pellet type thermostat housed in the forward (outlet) end of the intake manifold controls the circulation of water through the engine radiator. The pump is sealed against coolant leakage by a packless non-adjustable seal assembly mounted on the pump cover in position to bear against the impeller hub. 6K-1) The higher pressure raises the boiling point of the coolant and increases the cooling efficiency of the radiator. The vacuum valve is held against its seat by a light spring which permits opening of the valve to relieve vacuum created when the system cools off. The pump shaft and bearing assembly is pressed in the water pump cover. The inlet pipe cast in the pump cover feeds into the passage formed by the cover and the front face of the impeller. Vanes on the rotating impeller cause the coolant to flow radially outward through two discharge passages cast in the engine block.V-8 COOLING SYSTEM . a thermostat bypass. (Fig. open at all times. CHART pagt 6K-5 6K-5 6K-5 6K-6 6K-7 balancer. When the thermostat opens. The coolant then flows rearward through the water jacket which surrounds each cylinder barrel and extends below the lower limit of piston ring travel. 6K-2) The coolant is circulated by a centrifugal pump mounted on the front cover which forms the outlet side of the pump. These passages deliver an equal quantity of coolant to each cylinder bank water jacket. allows recirculation of coolant through the engine to provide rapid warm-up. Next. Fig. The 15 pound pressure cap used raises the coolant boiling point approximately 46°. The cooling system is sealed by a pressure type radiator filler cap which causes the system to operate at higher than atmospheric pressure. the coolant flows into the intake manifold water passage from the forward port of the cylinder heads to the thermostat housing and thermostat by-pass. The engine fan and pulley(s) are bolted to the pump shaft hub at its forward end. Page 6K-1 6K-1 6K-3 6K-3 6K-5 Subject REMOVAL INSTALLATION THERMOSTAT THERMOSTATIC VACUUM SWITCH-K-19 . (177°-182°F) coolant is directed to the upper tank of the radiator.8 ENGINE (Fig. which is mounted on the bearing shaft with the vanes facing rearward. Coolant flows through the inlet passage to the low pressure area at the center where it then flows rearward through three openings in the impeller.

6K-2 Engine Cooling Figs. 6K-2A and 6K-2B Engine Coolant Flow (V-8 Engine) .

NOTE: If belt tension on pulley is not released.Engine Cooling 6K-3 Fig. When the first two bolts are removed. FAN (Figs. when the thermostat is closed. Located in the coolant outlet at the front of the cylinder head is the outlet to the heater core from beneath the thermostat. the fan can be removed without disturbing the pulley by removing four attaching bolts. Coolant then flows through the coolant outlet and the pellet-type NOTE: For fan blade usage. During engine warm-up. The fan blades and pulley can be removed without disturbing the water pump or radiator. Coolant then flows through the block toward the rear.3 ) Engine Coolant Flow (L-6 Engine) thermostat to the radiator. The tension of the belt will keep the pulley in position. replace with aligning studs. A bellows-type seal is seated in the water pump body between the bearing and impeller. 6 K . water is redirected to the engine. 6 K .4 and 6 K . The inlet side of the pump is connected to the lower radiator tank by a hose. Above the pump inlet from the radiator is the inlet from the heater core. Some coolant is directed through a small hole in the cylinder head gasket to an area around each spark plug. On air conditioned equipped cars it will be necessary to detach fan shroud and slide it back over the fan. The water pump discharges coolant into the water jacket chamber between the front face of the block and the number one cylinder. . passing through two large cast openings into the cylinder head to cool the valve seats and forward to the front of the head. 6K-3 COOLING SYSTEM CIRCULATION L-6 ENGINE (Fig. refer to FAN BLADE IDENTIFICATION CHART.5 ) The centrifugal-type water pump contains an impeller which turns on a steel shaft which rotates in a ball bearing.

6K-5 Fan Installation (L-6) .6K-4 Engine Cooling Fig. 6K-4 Fan Installation (V-8 Engine) Fig.

Place thermostat in hot water 25° above the temperature stamped on the thermostat valve. With valve completely submerged and water agitated thoroughly. Torque nuts to 20 ft. 5. lbs. This is mounted in the housing at the cylinder head water outlet above the water pump. Use oil on the self-tapping bolts. 8. 6K-6 and 6K-7) Removal 1.7 W a t e r Pump Cross Section ( L . 2. Loosen pulley b e l t s and remove fan and pulley. 6. and 5/16" bolts to 25 ft. 3. 4. Apply a thin coat of 1050026 Sealer to the pump housing to retain the gasket. On air conditioned equipped cars install pulley and fan and clutch assembly. lbs. Inspect thermostat valve to make sure it is in good condition. 6K-8) 3. Install pulley and fan. the valve should close completely. 2. 7. r e move the clutch and fan assembly and pulley. re-install. Remove water pump attaching bolts. Refill cooling system. pull the pump straight out of the block to avoid damage to impeller.8 Engine) WATER PUMP (Figs. lbs. Torque self-tapping bolts to 13 ft. Remove radiator to water outlet hose. lbs. PERIODIC MAINTENANCE for recommended coolant.6 Water Pump Cross Section ( V . Remove the thermostat and place in water 10° below temperature indicated on the valve. 6 K . . Disconnect heater and bypass hose and lower radiator hose from pump. see Section 0. 3. (Fig. Installation 5. using a new housing gasket. Drain radiator.6 Engine) 4. Submerge the valve completely and agitate the water thoroughly. If new coolant is used. NOTE: On L-6 engines. Torque fan to pump bolts to 20 ft.fr Engine Cooling 6K-5 Fig. 4. then position ± e gasket on the housing. 1. Remove thermostat housing bolts and r e move water outlet and gasket from thermostat housing. Thermostats are designed to open and close at predetermined temperatures and if not operating properly should be removed and tested as follows: 1. If thermostat checks satisfactorily. Install the pump assembly. 2. On air conditioned equipped cars. Under this condition the valve should open fully. THERMOSTAT The thermostat consists of a restriction valve actuated by a thermostatic element. Fig. 6 K . Install pulley belt(s) and adjust belt tension using Tool BT-33-70-M.

there should be no vacuum at this port at idle. 6K-8 Water Pump Installation (V-8 Engine) Fig. a thermostatic vacuum switch is used to increase ignition timing advance at idle when higher coolant temperatures are encountered. there should be vacuum at the switch port " D " at idle. check distributor advance. This change from ported to fun vacuum advance at idle improves idle cooling If a heating problem exists at idle speeds only] disconnect the distributor vacuum hose at thermostatic switch. Refill cooling system. Fig. At temperatures below 230°. 6K-9 Thermostatic Vacuum Switch (K-19) . 6 K . If engine temperature is above 230° and vacuum is present at port " D " . THERMOSTATIC V A C U U M SWITCH DIAGNOSIS K-19 (Fig.6K-6 Engine Cooling 9. When engine temperature is above 230°.9 ) If equipped with air conditioning.

In. Exc.C. A. K19 Exc. A. K19 & A. A. A. 330 Cu. (L-6) Exc. K19 & A. K19 425 Cu.C. A.C.C. In.C. & K19 425 Cu. Exc. In. 400 Cu. & K19 330 Cu. In. 330 Cu.C. Exc. In. In. Exc. 425 Cu. 4 18" Number of Blades 4 Diameter 18" Identification Marks 622 (Painted on Blade) None 6 19" H (Stamped On Front of Hub) None None 6 5 19" 18" . (L-6) A. In.C. In. & K19 400 Cu. 400 Cu.Engine Cooling 6K-7 FAN BLADE IDENTIFICATION CHART Engine Usage 250 Cu. A. In. K19 & A.C. K19 250 Cu. Exc.C. A.C. In. In.C.

6K-8 Engine Cooling .

This pressure can cause the engine to blow out oil through the engine seals and gasket. At idle. VENTILATION VALVE DIAGNOSIS . 6L-4 6L-4 6L-5 6L-5 6L-6 6L-10 CRANKCASE VENTILATION SYSTEM (K-20) Description The purpose of the crankcase ventilation system is to burn crankcase vapors and prevent them from reaching the outside atmosphere and contaminating the air. L-6 CRANKCASE VENTILATION SYSTEM (Fig. Cars delivered in California use a closed ventilation system and all others use the standard system. high engine vacuum pulls the valve up against spring pressure and seats the valve.(K-19 & K-20) Crankcase Ventilating Systems 6L-1 CRANKCASE VENTILATING SYSTEM (K-19 & K-20) 33 THROUGH 86 SERIES CONTENTS OF THIS SECTION Subject CRANKCASE VENTILATION SYSTEM (K-20) DESCRIPTION L-6 VENTILATION SYSTEM V-8 VENTILATION SYSTEM CRANKCASE VENTILATION VALVE . 2. 4. This is necessary because at highway speeds crankcase pressure is high and more air and ventilation are needed to burn crankcase fumes. 6L-1) The standard ventilation system receives its outside air through a filtered oil filler cap. The air intake for this system is obtained from the filtered side of the carburetor air cleaner. V-8 CRANKCASE VENTILATION SYSTEM (Fig. The remainder of the system is the same for both standard and closed ventilation. 2. CRANKCASE VENTILATION VALVE DIAGNOSIS If sludging of the valve occurs it will not operate and the valve will be closed. Start the engine and adjust idle.) Both closed and standard systems use a plug type oil filler cap. The crankcase pressure is low at this time and requires very little venting. . Connect tachometer to the engine. (Front of the carburetor for the four barrel and the r e a r of the carburetor for the two barrel. . The closed ventilation systems oil filler cap is plugged so no air can be drawn through it. When the engine is stopped the valve is closed and prevents engine fumes from entering the manifold. through a calibrated orifice creating a smooth idle. At highway speeds the valve varies in location with engine vacuum. The fumes from the crankcase and valve cover are drawn through a spring loaded valve into the intake manifold by vacuum and burned in the combustion chamber. A quick check to see if rough idle is caused by the crankcase vent valve is to: 1. CRANKCASE VENTILATION VALVE The spring loaded valve serves four purposes. Air goes through a screened flame a r r e s t e r into a hose to the valve cover (left side of engine). 1. A plugged system will definitely cause a rough idle. This limits the amount of fumes which can be drawn into the intake manifold. 3. 6L-2) The difference between the two systems is the standard system receives intake air through a breather on the valve cover and the closed system receives air drawn from the snorkel end of the carburetor air cleaner to the filter and flame arrester on the left valve cover. Page 6L-1 6L-1 6L-1 6L-1 6L-1 6L-1 Subject AIR INJECTION REACTOR SYSTEM (K-19) DESCRIPTION PERIODIC MAINTENANCE PUMP REMOVAL PUMP DISASSEMBLY AND ASSEMBLY DIAGNOSIS Page . This will cause high crankcase pressure at highway speeds. From here air goes through the left valve cover and is circulated in the engine crankcase. Engine vacuum then draws the fumes up through a spring loaded valve into the intake manifold at the base of the carburetor. The valve is in a centering position allowing a greater area for fumes to pass through. In case of a backfire the valve is forced closed.

6L-2 Crankcase Ventilating Systems (K-19 & K-20) .

(K-19 & K-20) Crankcase Ventilating Systems 6L-3 .

6L-0 Vacuum Hose Routing . two check valves and hoses. NOTE: This system does not reduce the danger of inhaling any concentration of carbon monoxide in a confined area. air bleed control valve. separate from the Crankcase Ventilation System It is designed to reduce air pollution caused bv engine exhaust gasses by "treating" the unburned hydrocarbons and carbon monoxide as they are expelled from the combustion chamber into the exhaust manifold. the engine rpm will drop off more than 60 rpm. Clamp off the hose that goes from the valve to the carburetor base. the engine rpm will drop approximately 50 to 60 rpm. compresses clean filtered air which is distributed into the exhaust port of each cylinder. If the valve is working properly.1 9 ) CARS DELIVERED I N CALIFORNIA ONLY) DESCRIPTION The Air Injection Reactor System is entirely Fig. refer to GENERAL INFORMATION AND PERIODIC MAINTENANCE. driven by the engine. NOTE: All carburetors for this system have ported spark (vacuum for the distributor is taken above the throttle valves). There will be no change in engine rpm if the valve is sludged up and restricted. producing a "treated" exhaust that is below the maximum allowable level for air pollution. two manifolds. For Ventilation Valve maintenance recommendations. You should be able to hear the valve click shut when clamping off the line and releasing it several times. A sealed bearing pump. intake bleed valve. 4. Here it combines with the unburned hydrocarbons and carbon monoxode at high temperature causing a chemical reaction. SECTION 0. The Air Injection Reactor System consists of an air filter. Distributor vacuum AIR INJECTION REACTOR SYSTEM ( K .6L-4 Crankcase Ventilating Systems (K-19 & K-20) 3. If the valve is stuck open. air pump.

It also prevents back flow of exhaust gases through the system if air pump flow stops due to a broken belt or pump failure. A/C equipped cars. A relief valve in the air pump regulates pump pressure. the mixture in the intake manifold is too rich to burn and ignites when combined with the injected air in the exhaust manifold. use a thermostatic vacuum itch t 0 increase ignition timing advance at idle when higher coolant temperatures are encountered. 6L-3 Air Injection Reactor System Installation (330 cu. The check valve is in operation only when exhaust manifold pressure exceeds pump pressure. This valve is controlled by intake manifold vacuum and is required to prevent exhaust system backfires on deceleration. Section 1. engine) . The control valve will not let air into the intake bleed valve while at idle speeds. 6L-3 and 6L-4 illustrates the installation layouts for V-8 engines. Fig. For installation of K-19 pump. This change from ported to full vacuum advance at idle improves idle cooling. engines and 425 cu. 6L-0) The air pump compresses air drawn in through a silencer and filter. All 400 cu. in. L-6 engine does not use a control Refer to Fig. AIR INJECTION PUMP Removal 1. The air pump and valves require no special maintenance other than the normal belt inspection and adjustment. wash in kerosene. dip in SAE 10W-30 oil and squeeze to r e move excess oil. Fig. (Fig.000 miles (more often under dusty conditions). PERIODIC MAINTENANCE The Air Injection Reactor System polyurethane filter (V-8 only) should be cleaned every 12 months or 12. The pump forces air through a check valve into each engine exhaust port. refer to A/C. engines equipped with air conditioning. momentarily as the throttle is closed. 6L-1 for L-6 engine system layout. Remove filter element. in. NOTE: valve.(K-19 & K-20) Crankcase Ventilating Systems 6L-5 Hvance is dependent on throttle opening. The air intake bleed valve injects air into the intake manifold. 6L-2. in. On deceleration. Disconnect hoses at pump.

. Connect air pump inlet hose to short outlet tube on air silencer. NOTE: Do not submerge in solvent. damage to the permanently packed bearings may occur. noise will occur and dirt will be drawn into the air pump. Do not clamp or pry on the aluminum housing. 4. 3. Mark an alignment and rotor between two little ex(Fig. Tighten mounting screws. 6. NOTE: housing. 6L-4 Air Injection Reactor System Installation (425 cu. Connect hoses and tighten clamps. in. 6L-7) 4. (Fig. 2. 1. Position pump assembly on mounting bracket with holes lined up and install bolts loosely. NOTE: The long tube is the silencer and air inlet. Pull the vanes out of the rotor. Loosen bracket to pump mounting bolts and remove pump belt. 5. If hose is connected to the long tube. Discard carbon seal. Move pump until belt is tight using BT-33-70-M. Remove pulley. 5. Do not pry on the aluminum 3. Clean off the outside area of the pump. Remove rotor ring and carbon seal. Installation Disassembly (Fig.6L-6 Crankcase Ventilating Systems (K-19 & K-20) Fig. Clamp pulley hub in vise as shown in Fig. Remove bracket to pump mounting bolts and remove unit from car. 3. Install pump belt over pulley. engine) 2. 6L-8) Do not remove the bearings from the rotor. 6L-5) 1. Remove the with a 5/32" on the ring haust holes. 7. Remove the housing end cover by tapping with a soft (plastic) hammer on the boss of the large dowel pin and pull straight up. six rotor ring retaining screws Allen wrench. 6L-6 and remove the four housing end cover bolts. 2.

caked grease.(K-19 & K-20) Crankcase Ventilating Systems 6L-7 Fig. These blemishes indicate r e a r bearing failure. Fig. 6L-7 Removing Rotor Ring . If the front bearing or seal is to be replaced. Inspect the rear cover ground inner bearing race for grooves or scratches. Carefully pull out the carbon shoes with needle nose pliers and remove shoe springs. 6L-10. Rear bearing failure is also indicated by the absence of grease in the bearing. using a suitable puller as shown in Fig. NOTE: No further disassembly should be attempted as the rotor and housing are matched parts. and the bearing and cover assembly must be replaced. Wash out the six vane bearings and r e a r bearing with a cleaning solvent and repack with 1050525 Grease. The rear bearing may be replaced by pressing it out of the rotor ring. (Fig. CLEANING A N D INSPECTION To clean the rotor and housing assembly use only compressed air to blow out accumulated dust. The relief valve may be removed. 6L-5 Air Pump Exploded View 8. 9. the rotor and housing assembly is to be replaced. 6L-6 Clamping Pump In Vise Fig. Support the ring adequately to avoid distortion and press out of rotor ring. 6L-9) 10.

long end down Fig. scratches or discoloration indicate vane bearing failure. Broken edges require that the vanes be replaced. Assembly 1. This washboard condition is normal. 6 L . Before installing the vanes in the rotor. Damaged shoes must be replaced and springs positioned as described in PUMP ASSEMBLY. Grooves. 6L-9 Pressing O u t Rear Bearing Fig. The shoes will have small grooves from action of the thread structure of the vanes. 6 L . If bearings have failed. Turn remaining vane.1 0 Removing Relief Valve discoloration of bearing cage or rollers falling out of cage. All corners of the vanes should be square. notice their shapes. a new vane assembly and cover assembly are required. One vane has even cuts to both ends. Inspect the carbon shoe surface contacting the vane. Two vanes are longer on one end than on the other. This pin has been precision ground.1 1 I n s t a l l i n g Vanes i n Pump . but chipped or broken shoes are not.6L-8 Crankcase Ventilating Systems (K-19 & K-20) Fig. Using a 3/8" dowel. Inspect the vane pivot pin. 6 L .8 Removing Vanes From Rotor Fig. place the vane with even cuts to both ends and start the lower bearing over the dowel rod. Inspect the vanes for chips and cracks.

lbs. a V-shape will be formed with the wide part of " V " facing the assembly pin of the vanes. Push the vanes into the rotor with one vane contacting the stripper. 3. such as Loc-Tite or its equivalent and torque to 37 in. . 2. 6L-14) Remove the assembly dowel pin from vanes. 6L-11) Leave the dowel assembly pin until later. Three are cut deeper. (Fig. Push the spring flush ox beneath the rotor surface. When properly installed. P r e s s the rear bearing into the ring lettered end up.(K-19 & K-20) Crankcase Ventilating Systems 6L-9 Fig. Coat the six ring screws with a thread sealer. 6L-12 Vane and Shoe Location and start the lower bearing over the dowel rod. 6. Align the two dowel of the housing with the end cover holes. large and one small hole. 5. (Fig. (Fig. 6L-13) Install the ring and bearing assembly aligning alignment marks. 6L-13 Installing Rear Bearing 9. Curved portion of the spring is nearest the shoe. 6L-14 Installing Ring and Bearing Fig. Insert the three shoe springs into the deeper shoe slots. Install the end cover pivot pin the vane bearings. This will make all ends the same height when all the way on the dowel rod. 6L-12) Notice the size of the shoe slots. the into pins one Fig. Install carbon shoes with flat side to seat in slot and taper edge to face the vane. (Fig. Install end cover bolts and torque bolts to 10 ft. Clamp the pump drive hub in the vise. lbs. Position a new carbon seal (gasket) with the two elongated holes directly over cavity of rotor.

Excessive Pump Noise Check the drive belt tightness. (Fig. To install relief valve. Check that the pump mounting bracket is securely fastened. Care must be taken to keep foreign material from the bearings. Check belt tightness. However. a rolling sound. 2. As the pump operates at engine idle speed. c. use a suitable protecting plate over the valve and tap with a hammer until the valve shoulders on the housing. do not pry on the housing. Lightly touch the vane ends and tips with emery cloth where they show grooves worn from the housing. remove the r e a r cover. be taken in the a. is noticeable at all speeds. proceed with the following steps in the order given: a. Vane "chirping" is most noticeable at low speed and is heard intermittently. Bearing noise is easily distinguished from vane "chirping". If roughness or bumps are felt. but swing the pump into proper position by hand so the belt is tight (use BT-33-70-M). the pump must be disassembled. Check that hoses are not touching other parts of the car. if bearing noise increases to an objectionable level at certain speeds. Such a noise requires further inspection of the pump and removal from the car. Frequently vane " c h i r p " may be eliminated by increasing pump speed. 6L-15 Installing Relief Valve 10. do not. If it is determined that pump is not delivering air ence of air flow by removing the following steps should order given: the air injection (determine presan exhaust hose).) h. the bearing may have to be replaced with a new bearing to eliminate the noise. This sound does not necessarily indicate bearing failure. and the valve must be replaced. Failure has occurred if air escapes from the valve at engine idle speed. In tightening belt.6L-10 Crankcase Ventilating Systems (K-19 & K-20) d. The entire length of the hose system should be inspected.) f. Inoperative Pump Fig. 6L-15) NOTE: Care must be taken not to distort the aluminum housing. (See PUMP DISASSEMBLY and ASSEMBLY for correct procedure. A "chirping" or squeaking noise is most likely associated with vane rubbing in the housing bore. remove the three vanes. Air leaks around clamps can be located in the same manner or by daubing soap water on connections in question. With the pump running. Determine if all hoses are connected and have not vibrated free. (See PUMP DISASSEMBLY and ASSEMBLY for correct procedure. Extreme belt tension will damage the pump. under any conditions. Any air leaking will bubble soap water. If excessive noise is still present. Relief valve failure will cause excessive noise. Vane "chirping" is intermittent and is most noticeable at low speed. DIAGNOSIS 1. e. bearing noise. Check the pump relief valve. pry on the . check the entire system for leaks in the hoses and around clamps. If the belt needs tightening. With the pump removed from the car (See PUMP REMOVAL) rotate the drive hub three-quarters of a turn forward and onequarter of a turn backward. Failure of a r e a r bearing is identified by a continuous knocking noise. i . allowing the vanes additional wear-in time. b. If additional wear-in does not eliminate " c h i r p " . Following pump disassembly. g. breaks in hoses can be located by feeling for air blowing through any holes.

Disconnect 3/16 ID vacuum hose from bleed valve and p l u g hose end. Air should pass through valve from pump side only. Disconnect hose between intake bleed valve and control valve. Engine should be smooth when it returns to idle. (Use BT-33-70-M) Extreme belt tension will damage the pump. Inspect hoses. the pump must be removed and disassembled. air should flow through the control valve. bleed valve should draw air in for one to two seconds only. Air should blow from relief valve. an inoperative check valve can cause burned hoses from manifold to pump by exhaust back flow. 5. the intake bleed valve should not draw in any air. Inoperative Intake Bleed Valve With hose connections secure. Inoperative Relief Valve A relief valve stuck shut can cause pump failure and/or a burned exhaust system. a. flash throttle. As the pump operates at engine idle speed. Disconnect hose between control valve and intake bleed valve. a. b. b. Remove check valve and blow through valve. c. Check the entire system for leaks in the hoses and around clamps. d.(K-19&K-20) Crankcase Ventilating Systems 6L-11 housing. a. run engine 1000 rpm. If the intake bleed valve is stuck closed. it will draw no air. Plug both pump outlets. it will draw in air and engine idle will be extremely rough. b. Engine should be smooth when it returns to idle. Inoperative Control Valve With hose connections secure. If the valve is stuck in the open position. 6. no air will pass to the intake bleed valve and the engine will backfire on deceleration. b. . With engine speed at 1000 rpm. it will continue to draw air after one to two seconds and engine idle will be extremely rough. Plug valve inlet (15/16" diameter) and engine idle should return to normal. a. flash throt- tle. With engine at idle there should be no blow through control valve. Inoperative Check Valve If pump or belt fails. If the valve is leaking or stuck open. Determine if all hoses are connected and have not vibrated free. (Engine will backfire on deceleration) If bleed valve is stuck open. engine idle will be rough for three seconds after start or when throttle is flashed. breaks in hoses can be located by feeling a i r blowing through any holes. but swing the pump into proper position by hand so the belt is tight. Flash throttle. If each step in attempting to find the cause of no air delivery fails. Flash throttle. With car in neutral. 3. 4. The entire length of hose system should be inspected. If the valve is stuck closed.

6L-12 Crankcase Ventilating Systems (K-19 & K-20) .

6C-5 On Car Adjustments. It has a concentric float bowl. . 6M-109 4MV Carburetor Fig. engines. ADJUSTMENT CHOKE ADJUSTMENTS (ON OR OFF CAR) .. (Fig. refer to the appropriate sub-section (Model BV. YF.L. MODEL 2GC 34-36-38-52-56-58 Series Refer to Page6M-16. ADJUSTMENT SPECIFICATIONS Fig. in. ADJUSTMENT SPECIFICATIONS . . MODEL BV 33 & 35 Series-Except Air Injector Reactor System Subject DESCRIPTION REMOVE AND INSTALL DISASSEMBLY CHOKE AIR HORN FLOAT BOWL THROTTLE BODY CLEANING AND INSPECTION Page 6M-1 6M-2 6M-2 6M-4 6M-4 6M-4 6M-5 Subject ASSEMBLY Page THROTTLE BODY FLOAT BOWL AIR HORN FLOAT LEVEL ADJUSTMENT . and is used on all 250 cu. 6M-108 2GC Carburetor Fig. MODEL 4MV 34-36-38-52-54-56-58-84-86 Series Refer to Page 6M-23.6 Fig. 6C-6 On Car Adjustments-V-8 CARBURETOR USAGE CHART Refer to Page 6M-43. 6M-41 6M-42 6C-3 6C-5 MODEL BV CARBURETOR GENERAL DESCRIPTION The Rochester Model BV carburetor is a single barrel. . 6M-1) The Model BV carburetor incorporates several distinct features. FLOAT DROP. 2GC and 4MV). 6M-6 6M-6 6M-6 6M-7 6M-7 6M-7 6M-8 6M-9 MODEL YF 33 & 35 Series-Equipped with Air Injector Reactor System. except those equipped with K-19 (Air Injector Reactor System) for both a u t o m a t i c and manual transmissions. Refer to Page 6M-10. For the step by step disassembly and assembly procedure. . . downdraft model with provision for automatic choke mounted on the exhaust manifold.Model BV Carburetion 6M-1 CARBURETION ALL SERIES CONTENTS OF SECTION SPECIFICATIONS The specifications for Model 2GC and Model 4MV carburetors are found at the end of this section...

Regardless of the angle the car assumes. Disconnect fuel and vacuum lines. Disconnect accelerator rod. 2. Install attaching nuts. 6 M . Power. Disconnect choke rod. The choke rod can now be removed from the fast idle cam by 1. Connect fuel and vacuum lines. The Model BV carburetor incorporates the six systems of carburetion: Float. install air cleaner and gasket. prevents fuel loss on inclined roads. 2. INSTALLATION 1. A vacuum diaphragm unit mounted on the carburetor air horn opens the choke valve.3 ) 4. Remove the two attaching nuts and remove carburetor. 3. torque to 18 ft. This assembly contains the main metering jet and power valve. Position carburetor over mounting studs. Another feature of the carburetor is the unique design of the main well assembly. Idle. Connect choke rod. to a point where the cold engine will run without loading or stalling. CARBURETOR DISASSEMBLY CHOKE 1. Remove choke shaft lever screw (diaphragm side). Disconnect choke vacuum break hose at diaphragm unit and from pipe in throttle body.6M-2 Model BV Carburetion Fig. Engine heat cannot be directly transmitted from the float bowl into the main well area. The design of the float bowl. in conjunction with the centrally located discharge nozzle. lbs. 3. the fuel level is below the nozzle spill joint at all times. just after starting. remove two diaphragm bracket screws and r e m o v e vacuum b r e a k diaphragm assembly. . Remove air cleaner and gasket. 5. 2. It is attached to the carburetor air horn and is suspended in the float bowl. (6M-2) REMOVAL (Fig. The exhaust-mounted choke coil provides excellent choke response to supply the correct fuel mixtures to the engine during the warm-up period. Main Metering. On the Model BV carburetor the choke thermostatic coil is located on the exhaust manifold and is connected directly to the choke valve shaft by a connecting rod. Pump. 3. 5. Clean throttle body and manifold gasket surfaces and install new gasket over studs. and Choke. 6M-1 Model BV Carburetor which completely surrounds the main bore of the carburetor. Remove fast idle cam attaching screw. Then the fast idle cam and choke rod can be r e moved from upper choke lever by carefully rotating assembly upward and sliding end of rod out of upper choke lever. 4.

remove stake on the end of choke valve screws. 4. 6M-2 BV System rotating cam over end of rod. . Then remove the two choke valve attaching screws from the choke shaft and pull upward on choke valve to remove from shaft. Choke shaft and lever assembly can now be removed from air horn. To remove choke valve.Model BV Carburetion 6M-3 Fig.

7. filter spring and gasket between filter element and back side of inlet nut. (6M-4) 2. Remove main metering jet from bottom of main well support. Remove screw at base of main well support. Remove pump return spring from bottom of pump well. Remove float hinge pin and lift float assembly from air horn. 6. Pump discharge spring and ball may now be removed by inverting bowl and shaking into palm of hand. Remove the pump plunger from |he float bowl by pulling straight upward. Remove float needle seat and gasket with 1/2" bit screwdriver or special needle seatremoving tool. Place carburetor bowl with suction tube projected over edge of flat surface and remove two throttle body attaching screws. The anti-bubble screen located inside the main well should not be removed. THROTTLE BODY 1. 6M-3 Removing Float then remove the main well support from air horn. 5. Using a pair of long nosed pliers. 3. then remove power valve spring and ball. Remove idle mixture adjusting needle and . Remove four air horn attaching screws. 5. Clean and blow out dry with compressed air only. (6M-3) 4. Remove fuel filter inlet nut and gasket with 1" wrench. NOTE: Large open end of filter element always faces the fuel inlet nut. Fig. NOTE: Use care when removing power valve so as not to lose small spring and ball. Place air horn. Remove two hair pin clips from pump link and then remove pump link from throttle lever and pump plunger rod. AIR HORN 8. Remove air horn gasket. 6M-2A BV Carburetor Assembly Note position of choke trip lever in relation to upper choke lever tang for ease in reassembly. 1. NOTE: Do not remove vacuum break suction tube from throttle body. Remove power piston and power piston spring from air horn. Float needle may now be removed. Throttle body and gasket may now be removed. 3. NOTE: Do not remove idle pick-up tube from air horn as it is pressed in place. Then remove filter. on a flat surface. 9. 4.6M-4 Model BV Carburetion Fig. 2. remove pump discharge guide. Lift air horn straight up from bowl so as not to damage float. FLOAT BOWL 1. inverted. Remove hex head power valve check ball r e tainer from bottom of support.

BV Carburetor . Pump Return Spring 2 0 . 9. Clean in clean solvasol or equivalent. After cleaning. Pump Link 2 2 . Power V a l v e Assembly 16. Check float needle and seat for wear. a. NOTE: Do not pass drills or wires through calibrated jets or orifices as this may enlarge orifice and seriously affect carburetor calibration. Bowl .5 1. 11. If wear is noted. CLEANING A N D INSPECTION 1. Remove idle stop screw from throttle lever if necessary to replace. 6. 2. NOTE: Due to close tolerance fit of the throttle valve in the bore of the throttle body. 2.Exploded View 2 1 . Fuel I n l e f F i l t e r Assembly Va cuum Diaphragm Assembly Choke Lever Choke V a l v e Choke Lever Choke Shaft Choke Rod 8. Thoroughly clean carburetor castings and metal parts in carburetor cleaning solvent. 13. NOTE: Especially the following: Fig. 2. 7. Idle M i x t u r e N e e d l e and Spring 2 4 . 14. blow all passages and castings with compressed air and blow out all parts until dry. Vacuum Diaphragm Hose 2 5 . 3. 6 M . 10. A i r Horn Gasket 17. 3. T h r o t t l e Body Assembly 2 6 . 4. defective part must be replaced. Fig.4 Removing Pump Discharge Guide spring.Model BV Carburetion 6M-5 do not remove the throttle valve or shaft from the throttle body. Pump Discharge Check Assembly 18. Fast I d l e Cam A i r Horn Power Piston and Spring N e e d l e and Seat Assembly Float Float Pin M a i n W e l l Support Main Metering Jet 15. A c c e l e r a t o r Pump 19. 5. 6 M . Plastic vacuum break diaphragm unit should not be immersed in any cleaner. Check all parts for wear. NOTE: Pump Plunger and any synthetic or plastic parts should not be immersed in commercial carburetor cleaner. 12. T h r o t t l e Body Gasket 2 3 .

check to be sure that all air horn and gasket holes are in line. Thoroughly clean anti-bubble screen in main well. a new vacuum seal can be installed after carburetor is completely assembled. Using a new gasket.6M-6 Model BV Carburetion CARBURETOR ASSEMBLY THROTTLE BODY 1. . Place pump return spring in pump well and bottom spring in well by forcing downward with index finger. Check pump plunger vent ball to make sure it is free inside pump plunger head. 6. NOTE: Dog leg in pump link will face away from throttle shaft when installed correctly. if removed. Install float needle seat and new gasket. 2. Carefully insert p u m p discharge spring and guide on top of ball. 5. 6M-6 Installing Pump Discharge Ball FLOAT BOWL b. 6M-6) NOTE: The pump discharge guide is installed correctly when it is at right angles with the pump discharge jet. Check throttle and choke shaft bores in throttle body and air horn castings for wear or out of round. Place new air horn gasket on top air horn. Check relief spring for distortion. 3. If screen remains plugged. d. Check idle mixture needles for burrs or ridges. 4. Ends of link will protrude outward away from throttle body. using two screws and lockwashers. Check floats for leaks by shaking. h. Back needle out 1-1/2 turns as a temporary idle mixture adjustment. Screw idle mixture adjusting needle and spring into throttle body until it is finger tight. Replace plunger if leather or synthetic rubber is scored. attach throttle body to bowl. 3. hardened or damaged. Clean all dirt or lint out of the fuel inlet filter. 3. c. f. Inspect pump plunger. g. Inspect for burrs on the power piston or a distorted power piston stem or spring. replace it. using special tool or screwdriver with 1/2" bit. Install power piston spring and power piston in vacuum cavity. Install 3/16" steel ball into pump discharge cavity. AIR HORN 1. Check tank on float arm above float needle for wear and floats for dents. Tighten screws evenly and securely. e. 1. Tap the discharge guide lightly to seat flush with the float bowl casting. NOTE: If needed. replace main well support. This may be done by shaking. 2. Always use new gaskets in reassembly. 2. Fig. If filter remains plugged. Install idle stop screw in throttle lever. making sure not to curl rubber during installation. replace it if necessary. 4. If wear is noted on the steps of the fast idle cam. using two hair pin clips. NOTE: Piston should ride free in cavity. it should be replaced as it may upset engine idle during the engine warmup period. Install pump plunger assembly in bowl. (Fig. Install power valve ball (small steel ball). 4. Attach pump link to pump plunger rod and throttle lever. ball should rattle freely.

Install choke shaft lever to end of choke shaft (diaphragm side). 6. measure the distance from the air horn gasket to the bottom of each float. FLOAT DROP ADJUSTMENT Bend the float tang at the rear' of the float arm. as necessary. Tighten securely. (Fig. and retainer in main well support. 6M-7 Float. 11. move the choke shaft horizontally to obtain . Place float carefully in position with drop tang pointing downward towards air horn and install float hinge pin. Place float needle in float needle seat. aligning flats on lever with flats on choke shaft. 10. Install choke valve into the slot in the choke shaft. as necessary to obtain specified dimension from the gasket surface to the bottom of the float with the air horn held in the upright position and the float hanging free. next to the needle seat. 3. Tighten retainer securely. filter relief spring. 6M-7) Align floats by making sure they are parallel and centered in the air horn gasket cut-out. 2. Recheck float level adjustment if float alignment is necessary. filter element retaining in place with the fuel inlet nut and gasket. Install vacuum diaphragm unit and bracket to side of air horn. Install two choke valve attaching screws.casting.Level Adjustment Fig. retaining with two attaching screws. Install main support. NOTE: piston. Check for free motion of power metering jet in main well COMPLETION OF CARBURETOR ASSEMBLY 9. Bend the adjustment tang on float arm which contacts float needle. RP trademark should face upward. 4. CHOKE ASSEMBLY 6. Large side of lever will With the air horn inverted and gasket in place. FLOAT LEVEL ADJUSTMENT 1. Attach main well support to air horn assembly and tighten attaching screw securely. Assemble choke shaft into air horn from the throttle lever side. Install air horn to bowl assembly. Install filter gasket inside fuel inlet nut. 7. 6M-8 Float Drop Adjustment power valve spring. 8. (Fig. Then tighten the two choke valve attaching screws securely and stake in place. Install four air-horn-to-float-bowl attaching screws and tighten evenly and securely. Tang on the trip lever should be above the tang on the choke lever. 5. to obtain the specified dimension. Install upper choke rod lever on choke shaft. as shown. 5. Tang on the choke lever should point towards air horn.Model BV Carburetion 6M-7 Fig. being careful to lower the air horn straight down so that the floats will not be bent during installation. 6M-8) .020 clearance between the two levers. To insure proper end clearance between the choke trip lever and choke rod lever.

and screw on low step of cam. 6M-11 Choke Rod Adjustment . Adjust by turning valve on top of air horn. make sure the choke valve is held toward closed position so that the connecting rod is at end of the slot. 2. Install horseshoe clip in groove in rod end and pinch together. 6M-9 Idle Vent Adjustment To insure correct initial choke valve opening. Install the choke rod to the fast idle cam as shown. as needed. ends of rod face inward. adjust vacuum break as follows: Push the vacuum break diaphragm plunger in until seated. Install other end of rod into slot in choke lever. adjust using screwdriver. Fig. 6M-10 Vacuum Break Adjustment Fig. 7. IDLE VENT ADJUSTMENT 1. Install connecting rod to vacuum break diaphragm plunger by rotating end of rod so squirt on rod enters notch in plunger. Check clearance between air horn and vent valve. 3. In this position. (Fig. identification faces outward. If necessary. 9. 6M-9) VACUUM BREAK ADJUSTMENT Fig. Back idle speed screw out until free (choke open).6M-8 Model BV Carburetion 8. 6M-10) hang downward and part No. adjust rod so that specified gauge will fit between lower edge of choke valve and inside of air horn casting. Attach the fast idle cam to the throttle body assembly with the fast idle cam screw and tighten securely. Tighten securely. (Fig. To adjust. bend the connecting rod at the point shown. the idle vent valve should be open as specified. then carefully insert the upper end of the choke rod into the upper choke lever. With idle rpm set to specification. The dog leg of rod must face towards the idle mixture adjusting needle. just after engine starting. The steps on the fast idle cam should face towards the idle speed screw.

bend the choke rod to obtain specified clearance between the lower edge of the choke valve and the dividing wall of the air horn. .T. (Fig. with the throttle valves held wide open. UNLOADER ADJUSTMENT Disconnect upper end of choke thermostatic coil rod from choke lever.M.. Choke Rod Unloader Main Metering Jet Throttle Bore Vacuum Break 1-9/32" 1-3/4" 070" 1/2 to 1 Rod Dia.T.Model BV Carburetion 6M-9 Fig. 6M-13) Bend the unloader tang on the throttle lever as necessary to obtain specified dimension between MODEL BV SPECIFICATIONS AND ADJUSTMENTS Float Level Float Drop Idle Vent Auto. Choke Setting. Interference 090" A. bend rod as shown. The lower edge of the rod should be even with the top edge of the hole in choke shaft lever for maximum rod length while the rod should just line up with the hole for minimum rod length.T. NOTE: Make sure unloader arm does not interfere with fast idle cam screw after this adjustment. 6M-12 Unloader Adjustment CHOKE ROD ADJUSTMENT (Fig. . . Hold the choke valve completely closed and pull up on thermostatic coil rod to the limit of its travel.1 1 ) AUTOMATIC CHOKE ADJUSTMENT With the idle screw resting on the second step of the fast idle cam and against the shoulder of the high step. To adjust. 6M-12) Fig.T. 6M-13 Automatic Choke Adjustment the lower edge of the choke valve and the dividing wall of the air horn. 1-9/16" 140" A.T. (Fig. 350" 058" A. 6 M .060" S..160" M.100" M.. .

4. inlet filter nut. Position carburetor over mounting studs. Disconnect fuel and vacuum lines. Connect choke rod. Connect fuel and vacuum lines. filter and spring. float. Install attaching nuts. Remove 6 air horn screws (3 from body to air horn then 3 from air horn to boyd) and lift air horn straight up from body (to prevent float damage). The high speed circuit is controlled by a metering rod. 4. install air cleaner and gasket. 1. high speed circuit and accelerator pump circuit. 6M-25 Model YF Carburetor . grit. Place air horn up-ended on a flat surface and remove float hinge pin. DISASSEMBLY 1.6 engine when the "Air Injection Reactor System" is used. 6. Disconnect vacuum break hose at bowl and remove vacuum break assembly. 2. low speed circuit. 6M-12 6M-13 6M-13 6M-13 6M-14 The Model YF Carburetor with an automatic choke used in conjunction with a temperature sensing choke coil (mounted in a cast depression on the exhaust manifold) is used with the L. 6M-25) The Model YF Carburetor has the conventional float. (Fig. ADJUSTMENTS 3. then hold finger over pump discharge passage (to retain discharge needle) and operate the pump manually a few times to check Fig. 4. 5. 2. 2. Clean throttle body and manifold gasket surfaces and install new gasket over studs. 3. or metal particles in the fuel or in bottom of bowl. Remove air cleaner and gasket.6M-10 Carburetion Model YF MODEL YF CARBURETOR CONTENTS OF THIS SECTION Subject Page Subject Page DESCRIPTION REMOVE AND INSTALL DISASSEMBLY CLEANING AND INSPECTION ASSEMBLY BOWL AND THROTTLE BODY DESCRIPTION 6M-10 6M-10 6M-10 6M-11 6M-12 6M-12 ASSEMBLE AND ADJUST METERING ROD AIR HORN FLOAT ADJUSTMENT ASSEMBLE AIR HORN TO BOWL . Remove the two attaching nuts and remove carburetor. 3. . 5. Check the fuel bowl for evidence of dirt. lbs. Disconnect vacuum break link at choke lever by rotating vacuum break. Disconnect choke rod. Remove float needle seat using a wide screw driver. and float needle. REMOVAL 5. INSTALLATION 1. Disconnect accelerator rod. torque to 18 ft. Remove choke rod. The accelerator pump circuit and metering rod are mechanical and vacuum controlled.

then compress upper pump spring(s). metering rod. Remove pump housing screws from housing and diaphragm.Model YF Carburetion 6M-11 Fig.) 14. 7. Compress lower spring.ending carburetor bowl. The valve and shaft should not be removed unless shaft is binding or valve is damaged. If necessary. 9. (Fig. spring(s). Fig. remove retainer. 6. then remove screws and choke valve and slide choke shaft from housing. File staked ends of throttle valve screws flush with throttle shaft. Remove metering rod from metering rod arm. (Do not remove any pressed-in parts. the carburetor flange and air horn are disassembled as far as is necessary during an overhaul procedure. then remove diaphragm shaft retaining ring and slide diaphragm assembly out of housing. Remove diaphragm housing screws and lift out entire pump. 81—Pump and Metering Rod—Exploded V i e w Sea! Lifter Link Metering Rod Metering Rod Arm Idle Vent Assembly Retainer 7. 9. (Fig. 6M27) 11. . 6M-26) 10. remove the spring retainer and lower pump spring. 4. J2. Wash all metal parts in cleaning solvent and dry with compressed air. Upper Spring Retainer Lower Spring Screws Pump Housing Diaphragm Assembly 15. metering rod arm. Ordinarily. check ball and needle. then slide shaft out of flange. and pump lifter link assembly. disassemble as follows: 1. Loosen throttle shaft pump arm lock screw and remove arm and pump connector link. 3. 6M-26 Pump and Metering Rod Assembly operation of diaphragm. If either condition exists. Remove idle mixture screw and 2 remaining body-flange attaching screws and remove body and gasket from throttle flange. r e move idle vent screw assembly from lifter link. CLEANING AND INSPECTION 1. 11. 5. 2. 10. 6M27) 12. 6M-27) 13. 8. remove screws and throttle plate. Remove main metering jet and low speed (idle) jet. (Fig. and idle vent assembly. Empty the gas and remove pump discharge needle by up. 16. and passage restriction. (Fig. File staked ends of choke valve screws flush with shaft to prevent damage to shaft threads. 8.

6M-12 Carburetion Model YF 2. loosen lock screw. BOWL A N D THROTTLE BODY 1. press down on upper pump spring until pump bottoms out. adjust slightly and retighten screw. a n d tighten lock screw. Check choke valve and shaft for binding in air horn when assembled. Check float needle and seat for wear and r e place if necessary. Check f u e l clogging. and main 1. and back out 1-1/2 turns as an initial adjustment. cracks or 7. NOTE: Fig. upper spring(s) and spring retainer onto pump shaft. Align diaphragm with holes in housing. 12. 13. with throttle valve closed. 6M-28 Pump Connector Link Installation 9. . then install lower pump spring and retainer. 5. 10. Inspect pump diagragm for tears or holes and diaphragm housing for free intake check ball and clean passages. 6M-27 for pump and metering rod assembly. slide shaft into flange. 6. If idle vent screw assembly was replaced. Install pump connector link in throttle shaft pump arm. Place metering end through metering jet then bottom rod in casting and. NOTE: Refer to Fig. Assemble throttle flange to body casting using a new gasket. install new assembly onto pump lifter link. CAUTION: Do not use wire or other pointed instruments to clean drilled passages or calibrated openings. filter for chips. then metering rod arm. Install throttle valve screws. dents. Assemble pump lifter link. ASSEMBLE AND ADJUST METERING ROD 6. If disassembled. 4. Install low speed jet assembly metering jet. (Fig. 7. NOTE: Damage or excessive wear in throttle shaft bores necessitates replacement of the throttle flange to maintain position of drilled passages to throttle plate. support the shaft at the screwhead and stake the other end of the screws. 6M-29 shows the carburetor at this stage of assembly. 6M-28) NOTE: Linkage must not bind in any throttle position. Assemble diaphragm and shaft into pump housing and install retaining ring on shaft. Check throttle flange for surface squareness and for slop in shaft bores. 8. Check floats for leaks. Check all passages for clogging and blow clean with compressed air. guiding connector link end into pump lifter link. 3. Install throttle valve with lettering toward manifold side of flange and part number opposite idle port. 5. 2. 8. wear at lip and hinge pin. 6M-30) Metering rod arm should rest parallel on pump lifter link and metering rod eye should just slide over metering rod arm pin. Install pump discharge needle. (Fig. If binding occurs. 4. Install idle adjustment screw and spring lightly to its seat. then install screws (4) through housing and thread into diaqhragm 2 or 3 threads. then install arm over throttle shaft. ASSEMBLY 11. Adjust by bending metering rod arm. 3. Fig. 2. Install diaphragm assembly in place in carburetor body and tighten screws securely.

6M-29 ASSEMBLE A I R Bowl and Throttle Body . filter and inlet nut using new gaskets. Fig. cover and measure float level between float and cover at free (Fig. 6M-32 Float Drop Adjustment . 2. Install air horn gasket. 3. Adjust by bending stop tab on float arm. Hold cover in upright position (allowing float to hang down) and measure float drop from cover to float at end opposite hinge. Install air horn assembly and 6 attaching screws (one long screw installed through flange and body into air horn). 6M-31 Float Level Adjustment 2. needle. 6M-30 Metering Rod Adjustment Fig. BOWL ASSEMBLE A I R H O R N T O Refer to specification chart r e a r of this section. 1. float a n d float hinge pin with stop shoulder on hinge pin on side opposite carburetor bore.Model YF Carburetion 6M-13 Fig. Install choke rod and vacuum break assembly (if so equipped). 6M-31) Adjust by bending (not float arm) that r e s t s on 1. 2. lip of float needle. Install fuel filter spring. (lug 6M-32) 3.Assembled HORN 1. Invert bowl (the distance end of float). Install needle seat and gasket assembly. ADJUST FLOAT Fig.

ADJUST IDLE VENT (Fig. bend choke rod at offset to obtain a slight clearance (max. 6 M . 6M-34) .3 3 ) Fig. . Back idle speed screw out until free (choke open). This assures closed throttle valve. 6M-33 Idle Vent Adjustment Fig. (Fig. 2. If necessary. ADJUST CHOKE ROD (FAST IDLE) With choke valve fully closed.015") between fast idle cam and boss on carburetor bowl. 6M-34 Choke Rod Adjustment (Automatic Choke) ADJUSTMENTS Refer to SPECIFICATION CHART at the rear of this section. adjust using screw driver. 6M-36 Vacuum Break Adjustment 1. Check clearance between air horn and vent valve. 3. 6M-35 Choke Unloader Adjustment Fig.6M-14 Carburetion Model YF Fig.

index mark on fast idle cam must be at midpoint of fast idle tang on throttle lever. Tag Ident. Letters Float Level Float Drop Idle Vent Auto. (Fig. Bend fast idle tang up or down to adjust. 6M-34) CHOKE UNLOADER ADJUSTMENT With the throttle valve held wide open and the choke valve held toward the closed position with rubber band. bend unloader tang on throttle a lever to obtain the specified clearance between the lower edge of the choke valve and the air horn wall.36) MODEL YF SPECIFICATIONS AND ADJUSTMENTS Carb.035" 1/2 to 1 Rod Interference 260" . (Fig.Model YF Carburetion 6M-15 With choke valve fully closed. (Fig.300' . 6M. Choke Setting Unloader Choke Vacuum Break 4080S 1/2" 1-3/16" . bend the vacuum break link to obtain the specified clearance between the lower edge of the choke valve and the air horn wall. 6M-35) VACUUM BREAK ADJUSTMENT With the vacuum break arm held in against its stop and the choke valve held toward the closed position with a rubber band.

an external vent opens when the throttle valves are in the idle position. 6M-51 Float System Fig.5 2 .5 8 SERIES Subject Page Subject Page THEORY OF OPERATION FLOAT SYSTEM IDLE SYSTEM PART THROTTLE SYSTEM POWER SYSTEM PUMP SYSTEM CHOKE SYSTEM CARBURETOR ASSEMBLY REMOVE AND INSTALL 6M-16 6M-16 6M-16 6M-17 6M-17 6M-17 6M-17 6M-18 6M-18 DISASSEMBLY CLEANING OF PARTS INSPECTION OF PARTS ASSEMBLY COMPLETION OF CARBURETOR ASSEMBLY ADJUSTMENT CHART CARBURETOR USAGE CHART 6M-18 6M-20 6M-20 6M-20 6M-21 6M-41 6M-43 THEORY OF OPERATION There are six basic systems used in the Model 2GC. float.3 6 . 6 M .5 2 ) The idle system supplies the fuel required for normal curb idle. power. 6M-52 Idle System .5 6 . raises the float and closes the needle seat.5 1 ) The 2GC carburetor employs a single float. pump and choke. Fig.6M-16 Model 2GC Carburetion MODEL 2GC CARBURETOR 3 4 . idle. As fuel is consumed. FLOAT SYSTEM (Fig. part throttle. off idle and low speed operation. To minimize fuel vapor formation in the carburetor bowl. 6M-50 Carburetor Assembly Fig. maintaining correct fuel level in the float bowl under all operating conditions. the float drops and opens the needle seat. 6 M . I B U SYSTEM (Fig. Fuel then enters the float bowl.

When underhood temperatures rise. a tang on the unloader lever contacts the choke lever and holds the choke valve partially open to prevent a loading condition. PART THROTTLE (Fig. 6M-55 Pump System . To prevent a closed choke condition with a wide open throttle. CHOKE SYSTEM (Fig.Model 2GC Carburetion 6M-17 where air venturi. and into the POWER SYSTEM (Fig.5 4 ) When more power is needed or high speed driving is maintained.5 3 ) As the throttle valves open. 6M-53 Part Throttle System Cars equipped with factory installed A/C are equipped with an idle compensator to prevent stalling under prolonged "hot idle" conditions. Fig. The choke system is designed to work independently of the fast idle which provides a relatively short choking period with adequate fast idle for a cold engine. bleeds are provided. A thermostatic coil closes the choke valve for cold operation and gradually releases the choke during the warm-up period. This also provides an unloader to open the choke valve when starting a flooded engine.Power System Fig. 6 M . 6M-54 . the speed of air entering the carburetor bore increases and raises the vacuum in the small venturi area.5 6 ) Fig. To maintain a more exacting air-fuel ratio during warm-up. 6 M . 6 M . a bi-metal strip lifts the valve off its seat allowing additional air to enter below the throttle valves.5 5 ) The accelerator pump provides the fuel necessary for smooth operation during acceleration by forcing additional fuel into the air stream. permitting additional fuel to flow through the main well tubes. offsetting the enrichening effects of the higher temperatures. Fuel is then drawn from the float bowl into the main well. 6 M . PUMP SYSTEM (Fig. the power piston spring forces the piston down to unseat the spring loaded power valve. the force of the thermostatic coil is opposed by air velocity against the offset choke valve and a vacuum piston and link assembly. a vacuum operated power piston and power valve provide additional fuel. When manifold vacuum drops below approximately 9" hg.

Remove carburetor. 4. shield and vent. 6M-57) 2. To install. Fig. Remove throttle body to intake manifold nuts or bolts. (Fig. 5.6M-18 Model 2GC Carburetion Fig. Remove fuel inlet fitting and gasket. Disconnect choke pipe. Invert the air horn and place on a flat surface. float and needle assembly. Torque carburetor to intake manifold nuts or bolts to 14 ft. Mount carburetor on Holding Fixture BT-3014 or J-5923-B. Remove the idle vent valve retaining screw. 9. Disconnect vacuum lines. 6M-56 Choke System CARBURETOR ASSEMBLY REMOVE A N D INSTALL 1. 5. Disconnect linkage. then remove the float hinge pin. 3. Disconnect fuel line from carburetor. 6M-57 2GC Carburetor 2. then r e move the filter. Remove the power piston by depressing piston stem and allowing it to snap free. 4. If the pump lever and shaft or inner arm is to be replaced. 3. 7. (Fig. Remove air cleaner. 11. 6. Remove the air horn gasket. then lift the air horn straight up to remove. 6. Remove the retainer from the pump plunger shaft and remove pump plunger. loosen the set screw on the inner arm. 6M-5a Air Horn . reverse removal procedure and make adjustments outlined under ADJUSTMENTS (ON THE CAR). Fig. Remove retainer clip from the intermediate choke rod and unloader rod and remove the intermediate choke and unloader rods. 12. Remove the float needle and seat and gasket using Tool BT-52. Remove retainer spring clip from the upper end of the pump rod at the pump lever and disconnect the upper end of the pump rod. 7. 6M-58) 8. lbs. 10. Remove the eight air horn attaching screws. CARBURETOR DISASSEMBLY AIR HORN 1.

remove. 2. remove the pump discharge spring guide. 7.6 1 ) Fig. Invert float bowl and remove the three throttle body attaching screws. 6 M . NOTE: The cluster center screw is larger and has a gasket since it is located in the pump discharge passage. Fig. 4. 6M-61 Throttle Body and Choke . 4. then remove piston link and lever assembly. then r e move the choke lever and shaft with linkage from the choke housing. then remove aluminum ball check from bottom of pump well. 2.Model 2GC Carburetion 6M-19 13 If the choke valve or shaft is to be replaced. (Fig. Remove the choke housing gasket. choke valve shaft and unloader from the air horn. 3. then remove the choke valve. Remove the fast idle cam attaching screw. Remove the choke piston attaching screw. Remove the three choke cover attaching screws and retainers. THROTTLE BODY A N D CHOKE LINKAGE (Fig. The idle mixture needle screws may be r e moved for cleaning or replacement. 1. pump inlet filter screen and pump plunger return spring. then remove the cover and gasket. Remove the two choke housing attaching screws. 6. 5. 6M-60 Pump Discharge Guide 3. then remove the spring and steel ball. Remove baffle. If equipped with an idle compensator (factory installed air conditioned cars only) remove attaching screws and remove idle compensator and gasket. Remove venturi cluster attaching screws and remove cluster and gasket. 5. The piston can be removed from the link by removing the piston pin. Using a pair of needle-nosed pliers. 6 M . the two choke valve attaching screws. then remove the choke housing with linkage. then remove the throttle body and gasket.5 9 ) 1. Remove baffle plate from choke housing. 6M-59 Float Bowl Assembly Fig. FLOAT BOWL (Fig. 6M-60) 6. Remove main metering jets and power valve.

gasket. 5. 5. Place a new gasket on the bottom of the float bowl with holes aligned. 3. jets and power 5. the worn parts should be replaced. 6. If filter is plugged. If removed. Install the fast idle speed screw and spring in the lever. Install the intermediate choke lever and shaft. Install the choke piston lever and link assembly in the choke housing. 3. Install the choke housing gasket. 8. Install the main metering valve. 9. Install the pump inlet screen and the baffle in the float bowl. then back out 1-1/2 turns as a preliminary idle adjustment. with linkage attached. (Fig. Position the fast idle cam on the throttle body and install attaching screw. 4. 6M-60) 2. it should be replaced. install the slow idle speed screw. 9. 2. Tighten finger tight. If removed. CARBURETOR ASSEMBLY THROTTLE BODY (Fig. fast idle cam and throttle shaft lever. Shake float to check for leaks. 6. Inspect the upper and lower surfaces of the float bowl to see that the small sealing beads are not damaged. Inspect the idle mixture adjusting needles for burrs or ridges. 7. If damaged. If removed. and CAUTION: The choke coil. 1. in the choke housing. . housing and pump plunger should not be immersed in solvent. Damaged beading may r e sult in air or fuel leaks at that point. Tighten screws evenly and securely. If worn. If holes are worn excessively or out-of-round to the extent of improper operation of the carburetor. 7. Do not overtighten. 3. If grooved. 1. Examine float needle and seat. 3. using two self-tapping screws. Do not pass drills through jets or passages. If equipped with idle compensator. Install the pump discharge (steel) ball. Inspect holes in pump rocker arm. Install the pump inlet (aluminum) ball and the pump return spring in the pump well. then position the throttle body on the gasket and install the three attaching screws. replace cam to assure proper engine operation during the warm-up and choking periods. install the fast idle lever on the end of the throttle shaft with attaching screw. install the idle mixture needles and springs in the throttle body. install the choke piston on the link so that the piston hole is facing outward. install compensator and gasket between the two large venturi. Clean and dry all passages in casting with compressed air. FLOAT BOWL 1. Install the venturi cluster. If removed. 8.6M-20 Model 2GC Carburetion NOTE: No attempt should be made to r e move the throttle valves or shaft as it may be impossible to reassemble the throttle valve correctly in relation to the idle discharge orifices. replace the pump plunger as an assembly. seat and gasket assembly. Replace if necessary. then position the choke housing on the throttle body and install the two attaching screws. Inspect the steps on the fast idle cam for excessive wear. Inspect the throttle body to make sure idle passages and vacuum channels are open.. 2.6 1 ) 1. then install the attaching screw. replace with a new matched float needle. 4. Clean pump in clean gasoline only. Clean filter of dirt or lint. Check float for dents or excessive wear at hinge pin holes. INSPECTION OF PARTS CLEANING OF PARTS The carburetor should not be cleaned in any solution other than a cold immersion type cleaner. Thoroughly clean carburetor castings metal parts in carburetor solvent. Screw with gasket must be inserted in center hole. 6 M . 4. and attaching screws. Inspect the pump plunger for cracks or creases. The lever should extend upward between the attaching screw bosses. 2. spring and guide in the passage in the venturi cluster mounting surface.

Install the pump plunger shait in tne pump lever so that the end is pointing inward. Install the air horn on the float bowl while . See adjustment specification chart. FLOAT DROP ADJUSTMENT If necessary to adjust. See adjustment specification chart. Bend the tang toward the seat to decrease the float drop and away from the seat to increase the drop. 6. FLOAT LEVEL ADJUSTMENT Fig. position the pump inner lever in the air horn. 5. then install choke valve in the choke shaft with the letters RP facing upward. a. Install choke unloader rod into unloader lever (end of rod facing inward). recheck the float level setting. NOTE: Lubricate shaft with light grease. Make sure the float is properly aligned on the air horn. Then connect lower end of rod to fast idle lever. 4. 2. retaining with clip. then install the inlet fitting and gasket.6 2 ) 1. Then connect lower end of rod to intermediate lever retaining with horseshoe clip. Install the choke shaft in air horn by inserting it from the choke side. install the pump lever and shaft and tighten retaining screw. Make adjustment as outlined in adjustment specification chart. If it is necessary to bend the float arm for alignment purposes. Install and tighten the eight air horn screws evenly and securely. bend the float tang which contacts the needle seat. Install seat in air horn with BT-52. 5. Make sure piston travels freely. Tang on unloader lever faces outward. Install the air horn gasket. Position the float needle seat gasket and small filter screen on the seat. 3. 7. Center the choke valve before tightening choke valve screws. Install the power piston and lightly stake the casting. 2.Model 2GC Carburetion 6M-21 AIR HORN i if removed.020" clearance should be maintained between choke unloader lever and the air horn casting. install choke unloader lever on choke shaft. Position idle vent valve and shield on air horn and retain with attaching screw. If removed. 6. Install the choke valve screws. Tighten choke valve screws and stake lightly in place. 3. . Position the upper end of the pump rod on the pump lever and retain with spring clip. COMPLETION OF CARBURETOR ASSEMBLY (Fig. float and needle assembly and float hinge pin. 6 M . 6M-62 Carburetor Assembly guiding accelerator pump in place. Install the fuel iniet filter screen with the closed end inward. 4. Install intermediate choke rod into upper choke lever (end of rod facing inward). then install the retainer.

6M-22 Model 2GC Carburetion .

6M-75 Float System .23 MODEL 4 M V CARBURETOR Subject Page Subject Page GENERAL DESCRIPTION THEORY OF OPERATION FLOAT SYSTEM IDLE SYSTEM OFF IDLE OPERATION HOT IDLE COMPENSATOR MAIN METERING SYSTEM POWER SYSTEM AIR VALVE DASHPOT ACCELERATING PUMP SYSTEM CHOKE SYSTEM CARBURETOR REMOVE AND INSTALL 6M-23 6M-24 6M-24 6M-24 6M-26 6M-26 6M-26 6M-27 6M-29 . . 6M-30 6M-31 6M-32 CARBURETOR DISASSEMBLY 6M-32 AIR HORN REMOVAL 6M-33 AIR HORN DISASSEMBLY 6M-33 FLOAT BOWL DISASSEMBLY 6M-33 THROTTLE BODY DISASSEMBLY . The primary (fuel inlet) side has small bores with a triple venturi set-up Fig. Fuel metering in the primary side is accomplished with tapered metering rods positioned by a manifold vacuum responsive piston. GENERAL DESCRIPTION The Quadrajet is a 4-barrel carburetor having two stages of operation. 6M-36 CLEANING AND INSPECTION 6M-36 CARBURETOR ASSEMBLY 6M-37 THROTTLE BODY 6M-37 FLOAT BOWL 6M-37 AIR HORN 6M-38 AIR HORN TO BOWL INSTALLATION . Its metering principles are similar to most plain tube carburetors using the venturi principle. . . .Model 4MV Carburetion 6M. 6M-39 ADJUSTMENTS 6M-40 ADJUSTMENT CHART 6M-41 equipped with plain tube nozzles.

idle. The fuel reservoir is centrally located and uses a single float pontoon. The float system operates as follows: Fuel from the engine fuel pump enters the carburetor fuel inlet passage. When the throttle valves are in the engine idle position. This fuel passage leads upward to a point just above normal liquid level and the fuel spills over into the float bowl. hooks over the center of the float arm above the needle valve. an actuating link on the pump lever strikes the spring arm on the idle vent valve. The same pressure in the float valve chamber also acts upon the small diaphragm fastened to the top of the float valve stem. a balanced air/fuel mixture ratio can be maintained during part throttle and power operation because the same pressure acting upon the fuel in the float bowl will be balanced with the air flow through the carburetor bores. This block prevents fuel slosh on severe brake applications. The internal vent tubes allow the escape of fuel vapors in the float chamber during hot engine operation. During hot engine soak. IDLE SYSTEM (Fig. A float needle pull clip. When the throttle valves are opened to the offidle and part throttle. As incoming fuel fills the float bowl to the p r e scribed fuel level. The purpose of the internal vents is to balance incoming air pressure beneath the air cleaner with air pressure acting on fuel in the float bowl. float valve diaphragm retainer and screws. The primary side of the carburetor has six systems of operation. The following text describes all systems of operation in detail for ease in servicing and troubleshooting. returning the carburetor to the internally balanced venting. fuel is metered in direct proportion to the air passing through the secondary bores. power. main metering. This prevents fuel vaporization from causing excessive pressure build-up in the float bowl. A sintered bronze fuel inlet filter is mounted in the fuel inlet casting which is an integral part of the float bowl. 6M-76) The idle system is used only in the two primary bores of the carburetor. This maintains a more constant fuel level during this type maneuver. which can result in fuel spillage into the carburetor bores. plastic float pontoon assembly. an external idle vent valve is used to vent fuel vapors to the outside. The carburetor float chamber is both internally and externally vented. It has the ability to remove dirt particles of 80 microns (. This cycle continues. Its purpose is to assist in lifting the float valve off its seat whenever fuel pump pressure or the fuel level in the float bowl is low. a float valve and diaphragm assembly. The float needle valve is pressure balanced to permit use of a small float to control fuel "shut-off" through the large fuel inlet needle seat. 6M-75) The float system consists of a float chamber. the fuel vapors are allowed to vent externally. thereby preventing them from entering the carburetor bores and being drawn into the engine. The pressure on this diaphragm tends to force the float valve upward and pull the float valve off its seat. The secondary side has one metering system which supplements the primary main metering system and receives fuel from a common float chamber.003") in diameter. pump. constantly maintaining a positive fuel level in the float bowl. This prevents rough engine idle and excessively long hot engine starting. and retainer combination. Each bore has a separate . the idle vent valve closes.6M-24 Model 4MV Carburetion The secondary side has two very large bores which have greatly increased air capacity to meet engine demands. located on the top of the primary side of the air horn. shutting off all fuel flow.position. As fuel is used from the float chamber the float drops and allows more incoming fuel to enter the float bowl until the correct fuel level is reached. Therefore. fastened to the float valve stem. It passes through the filter element and on into the float inlet valve chamber. A plastic filler block is located in the top of the float chamber in the area just above the float valve. float hinge pin. and a float valve pull clip. The fuel enters the chamber above the float valve tip and due to pressure tends to force the float needle downward (closed). and opens the valve. The fuel enters the float chamber at the top to prevent incoming fuel vapors from mixing with solid fuel in the bottom of the float bowl and disrupting good carburetor metering. Thus. Internal vent tubes are located in the primary bore section of the carburetor air horn just above the float chamber. the float pontoon rises and forces the fuel inlet valve closed. THEORY FLOAT SYSTEM (Fig. The fuel p r e s sure acting on the diaphragm raises the needle off its seat. and choke. Using the air valve principle. They are float. allowing fuel to pass by the open float valve and enter the fuel passage leading to the float chamber. to prevent stalling. The air valve principle is used in the secondary side for metering control and supplements fuel flow from the primary bores.

It passes from the main fuel well into the idle passage where it is picked up by the idle tubes. idle channel restrictions. idle air bleeds. With the idle discharge holes in a very low pressure area and the fuel in the float bowl vented to atmosphere (high pressure). The air/fuel mixture then moves down to the idle needle discharge holes. The fuel is mixed with air at the top of each idle tube through an idle air bleed. During curb idle the throttle valve is held slightly open by the idle speed adjusting screw. It then passes down the idle channel past the lower idle air bleed holes and off-idle discharge ports. The fuel is metered at the tip of the idle tubes and passes up through the idle tubes. Since the engine requires very little air for idle and low speeds. fuel is added to the air to produce a combustible mixture by the direct application of vacuum (low pressure) from the engine manifold to the idle discharge hole below the throttle valve. They consist of idle tubes. It then enters the intake manifold and is conducted to the engine cylinders as a combustible mixture. 6M-76 Idle System and independent idle system. The fuel mixture then crosses over to the idle down channels where it passes through a calibrated idle channel restriction. where it enters the carburetor bores and mixes finally with air passing around the slightly open throttle valve.Model 4MV Carburetion 6M-25 Fig. The idle mixture needles are adjustable and control the amount of fuel mixed with the air going to the engine. the idle system operates as follows: Fuel is forced from the float bowl down through the primary metering jets into the main fuel well. just above the primary throttle valves where it is mixed with more air. idle mixture adjustment needles. Turning the mixture screw clockwise (inward) decreases the fuel discharge (gives a leaner mixture) and turning the mixture . and idle discharge holes. The small amount of air which passes between the primary throttle valve and bore is regulated by this screw to give the engine the desired idle speed. idle passages.

air velocity increases in the carburetor venturi. As the primary throttle valves open. OFF IDLE OPERATION As the primary throttle valves are opened from curb idle to increase engine speed. A seal is used between the compensator valve and the float bowl casting. to a point below the secondary throttle valves. MAIN METERING SYSTEM (Fig. resulting in rough engine idle and stalling. they pass by the off-idle ports. plug the hole or cool engine down to a point where the valve is closed for proper idle adjustment. as the plug must be removed before the air cleaner is installed. a bi-metal strip which is heat sensitive. This uncovers the air channel leading from the valve chamber to the point below the throttle valves.6M-26 Model 4MV Carburetion screw counterclockwise (outward) increases (enrichens) the idle fuel mixture. just beneath the air cleaner. The purpose of the bleed is to allow any fuel vapors in the idle tube channel during hot idle to escape and prevent them from mixing with fuel being picked up by the idle tube. At a predetermined temperature. In order to insure proper idle adjustment when the engine is hot. Otherwise the compensator will not function if the plug is left in the hole. This gives a more consistent idle fuel mixture during periods of hot engine idling. It should be noted there is an idle air bleed located in each idle tube. The valve closes off an air channel which leads from a hole in the top of the air horn. additional fuel is needed to combine with the extra air entering the engine. Since the low pressure (vacuum) is now in the smallest boost venturi. gradually exposing them to high engine vacuum below the throttle valves. Manifold vacuum is supplied through a channel to the vacuum operated power piston connected to the primary main metering rods. When the engine cools and the extra air is not needed. The air bleed leads from the top of this channel into the top of the main fuel well where it is vented into the air horn above the venturi. fuel begins to discharge from the lower idle air bleed holes and continues to do so throughout operation of the part throttle to wide open throttle ranges. the bimetal strip bends and unseats the compensator valve. This allows enough air to be drawn into the engine manifold to offset the richer mixtures and maintain a smooth engine idle. The compensator consists of a thermostatically controlled valve. Its purpose is to offset enrichening effects caused by excessive fuel vapors during hot engine operation. main well air bleeds. The system operates as follows: During cruising speeds and light engine loads. engine manifold vacuum is high. Fuel flow from the float bowl is metered between the metering rods and main metering jet orifice. Normally the compensator valve is held closed by tension of the bi-metal strip. During extreme hot engine operation.venturi which is increased many times in the double boost venturi. NOTE: Plug the compensator hole with something that will be seen. a valve holder and bracket. a finger may be held over the compensator air inlet channel located on top of the air horn. the bi-metal strip closes the valve and operation returns to normal mixtures. vacuum operated metering rods. fuel discharge nozzles. To check this. This is accomplished by the slotted off-idle discharge ports. The idle needle holes and off-idle discharge ports continue to supply sufficient fuel for engine requirements until air velocity is high enough in the venturi area to obtain efficient fuel flow from the main metering system. and triple venturi. fuel flows from the main discharge nozzles as follows: Fuel flows from the float bowl through the main metering jets into the main fuel well and is bled . If the valve is open. As a result. Manifold vacuum holds the main metering rods down in the main metering jets against spring tension. The additional fuel added from the off-idle ports mixes with the increasing air flow past the opening throttle valves to meet increased engine air and fuel demands. If no drop in engine rpm is noted on the tachometer. the compensator valve must be closed. the valve is closed. HOT IDLE COMPENSATOR The hot idle compensator is located in a chamber at the r e a r of the carburetor float bowl adjacent to the secondary bores. excessive fuel vapors en- tering the engine manifold cause richer than normally required mixtures. This causes a drop in pressure in the large. Further opening of the throttle valves increases the air velocity through the carburetor venturi sufficiently to cause low pressure at the lower idle air bleeds. supplementing the main discharge nozzle delivery. main fuel well. As the primary throttle valves are opened beyond the off-idle range allowing more air to enter the engine manifold. The compensator valve assembly is held in place by the dust cover over the valve chamber. when extra air is needed to offset the enrichening effects of fuel vapors. 6M-77) The main metering system consists of main metering jets.

The spring located beneath the vacuum operated power piston tends to push the piston upward against manifold vacuum. as engine load is increased to a point where extra mixture enrichment is required. manifold .7 8 ) vacuums are sufficient to hold the power piston down against spring tension so that the larger diameter of the metering rod tip is held in the main metering jet orifice. The secondary section contains throttle valves. the secondary side of the carburetor is used. the vacuum overcomes the power piston spring tension and returns the larger portion of the metering rod into the metering jet orifice and back to normal economy ranges. 6M-77 Main Metering System with air from the vent at the top of the main well and side bleeds (one which leads from inside the bore area above the venturi and another from the cavity around the main fuel nozzle into the main well). however. as the engine speed increases. spring loaded air valves. To meet these demands. However. When manifold vacuum rises and mixture enrichment is no longer needed. POWER SYSTEM (Fig. The secondary side operates as follows: The power system in the Quadrajet carburetor provides extra mixture enrichment for power requirements under heavy acceleration or high speed operation. The power system located in the primary side consists of a vacuum piston and spring located in a cylinder connected by a passage to intake manifold vacuum. The fuel in the main well is mixed with air from the main well air bleeds and then passes through the main discharge nozzle into the boost venturi. The smaller diameter of the metering rod tip allows more fuel to pass through the main metering jet and enrich the mixture flowing into the primary main wells and out the main discharge nozzles. metering orifice discs. the primary side of the carburetor can no longer meet the engine air and fuel requirements. fuel discharge nozzles. main fuel wells with air bleed tubes. secondary metering rods. the spring tension overcomes the vacuum pull on the power piston and the tapered primary metering rod tip moves upward in the main metering jet orifice. and accelerating wells and tubes. 6 M . At the boost venturi the fuel mixture then combines with the air entering the engine through the carburetor bores and passes through the intake manifold and on into the engine cylinder as a combustible mixture.Model 4MV Carburetion 6M-27 Fig. The richer mixture is supplied through the main metering system in the primary and secondary sides of the carburetor. Mixture enrichment is not necessary at this point. On part throttle and cruising ranges.

6 M . The secondary main discharge nozzles (one for each secondary bore) are located just below the air valve and above the secondary throttle valves. Fuel flows from the float chamber through the secondary orifice discs into secondary main wells. They. where it is mixed with air from the main well tubes. The cam pushes on a lever attached to the secondary main metering rods. As the valve passes the port it exposes the port to manifold vacuum.7 8 Power System When the engine reaches a point where the p r i mary bores cannot meet engine air and fuel demands. This allows the required air for increased engine speed to flow past the air valve. As air flow through the secondary bores creates a low pressure (vacuum) beneath the air valve. The metering rods are tapered so that fuel flow through the secondary metering orifice discs is directly proportional to air flow through the secondary carburetor bores. begins to open the secondary throttle valves. In this manner correct air/fuel mixtures to the engine through the secondary bores can be maintained by the depth of the metering rods in the orifice discs. being in the area of lowest pressure. The cam pushes the lever upward. The accelerating ports will prevent a momentary leanness as the valve opens and the secondary nozzles begin to feed fuel. raising the metering rods out of the secondary orifice discs. Here fuel mixture is mixed with air traveling through the secondary bores to supplement the air/fuel mixture delivered from the primary bores. The accelerating ports will continue to feed fuel until the fuel in the accelerating wells is depleted. increased air flow through the secondary side of the carburetor opens the air valve to a greater degree which in turn lifts the secondary metering rods further out of the orifice discs. The port will immediately start to feed fuel from the accelerating wells. The air emulsified fuel mixture travels from the main wells to the secondary discharge nozzles and into the secondary bores. and engine speeds increase. and then goes on into the engine manifold and on to the engine cylinders as a combustible mixture. As the throttle valves are opened further.6M-28 Model 4MV Carburetion Fig. When the air valve begins to open. the upper edge of the air valve passes the accelerating well port. begin to feed fuel as follows: When the air valve begins to open it rotates a plastic cam attached to the center of the main air valve shaft. atmospheric pressure on top of the air valve forces the air valve open against spring tension. . the primary throttle lever through connecting linkage to the secondary throttle shaft lever.

The milled slot allows enough fuel to bypass the orifice disc to keep the main well filled during this period. They extend up and around the secondary fuel discharge nozzles. During hot engine idle or hot soak the fuel could boil away out of the fuel well. These are necessary because when the air valve is in the closed position. 3. 6M-79 Air Valve Dashpot The depth of the main metering rods in the orifice discs in relation to the air valve position are factory adjusted to meet the air/fuel requirements for the specific engine model. Two baffle plates are used. Their purpose is to provide good fuel distribution at lower air flows by preventing too much fuel from going to the front of the engine.7 9 ) The secondary air valve has an attached piston assembly which acts as a dampener. This insures immediate fuel delivery from the secondary fuel wells at all times. The secondary metering rods have a slot milled in the side to insure adequate fuel supply in the secondary fuel wells. The rod has a rubber seal which retains the dampener piston to the plunger rod and also acts as a valve. 6 M . The motion of the piston is retarded by fuel which must bypass the piston when it moves up in the fuel well. The main well bleed tubes extend below the fuel level in the main well. The purpose of the valve is to seat on the piston when the air valve opens and the piston rod moves upward. No further adjustment should be required. 1. the secondary metering rods are nearly seated against the secondary metering orifice discs.Model 4MV Carburetion 6M-29 Fig. There are three other features incorporated in the secondary metering system which are as follows: . AIR VALVE DASHPOT (Pig. one in each secondary bore. 2. The dampener piston operates in a well which is filled with fuel from the float bowl. to prevent oscillation of the valve due to engine pulsations. These actually bleed air into the fuel in the well to quickly emulsify the fuel with air for good atomization as it leaves the secondary discharge nozzles. The piston is attached loosely to a plunger rod. This closes off the area through the center of the piston and slows down the air valve opening to prevent secondary discharge nozzle lag.

operating in a fuel well. as happens during throttle closing. When the primary throttle valves are opened the connecting linkage forces the pump plunger downward. tends to lag behind causing a momentary leanness. a momentary acceleration lag could result. when the throttle is opened rapidly. plunger is spring spring is balanced spring so that a fuel is delivered The pump discharge check ball seats in the pump discharge passage during upward motion of the pump plunger so that air will not be drawn into the passage. This also vents any vapors which may be in the bottom of the pump well so that a solid charge of fuel can be maintained in the fuel well beneath the plunger head. (The cup moves up and down on the pump plunger head). 6M-80 Accelerating Pump System ACCELERATING PUMP SYSTEM (Fig. 6 M . The pump plunger is operated by a pump lever on the air horn which is connected directly to the throttle lever by a pump rod. The pump plunger is of a floating type. The accelerator pump is used to provide the extra fuel necessary for smooth operation during this time. The top pump duration with the bottom pump return smooth sustained charge of during acceleration. It consists of a spring loaded pump plunger and pump return spring. . fuel from the float bowl enters the pump well through a slot in the top of the pump well. When the pump plunger is moved upward the flat on the top of the cup unseats from the flat on the plunger head and allows free movement of fuel through the inside of the cup into the bottom of the pump well. which is heavier. The pump cup seats instantly and fuel is forced through the pump discharge passage.8 0 ) During quick acceleration. otherwise. It should be noted the pump loaded. When the pump plunger moves upward in the pump well. where it unseats the pump discharge check ball and passes on through the passage to the pump jets located in the air horn where it sprays into the venturi area of each primary bore.6M-30 Model 4MV Carburetion Fig. The fuel. the air flow and manifold vacuum change almost instantaneously. The accelerating pump system is located in the primary side of the carburetor. It flows past the synthetic pump cup seal into the bottom of the pump well.

During engine cranking. A cavity just beyond the pump jets is vented to the top of the air horn. This restricts air flow through the carburetor to provide the richer starting mixture required. When the choke valve is closed. The thermostatic coil located in the engine manifold is calibrated to hold the choke valve closed when the engine is cold. 6 M . vacuum break modulating spring. This acts as a suction breaker so that when the pump is not in operation fuel will not be pulled out of the pump jets into the venturi area. The vacuum break modulating spring allows the vacuum break (choke valve position) to vary according to ambient temperature. The air valve is locked closed until the engine is thoroughly warm and choke valve is wide open.8 1 Choke System During high speed operation. air valve lockout lever. NOTE: To close the choke valve the primary throttle valves have to be partially opened to allow the fast idle cam follower to bypass the steps on the fast idle cam and come to rest on the highest step of the fast idle cam. The choke system consists of a choke valve located in the primary air horn bore. When the engine starts and is running manifold vacuum applied to the vacuum diaphragm unit mounted on the float bowl will open the choke valve to a point where the engine will run without loading or stalling. the air valve lockout lever is weighted so that a tang on the lever catches the upper edge of the air valve and keeps the air valve closed. It results in more vacuum break at higher temperature (75° F+) and less vacuum break at cooler temperature. a vacuum diaphragm unit. This insures a full pump stream when needed and prevents any fuel "pull over" from the pump discharge passage. Choke operation is controlled by the combination of intake manifold vacuum. connecting linkage. a vacuum exists at the pump jets. outside the carburetor bores.Model 4MV Carburetion 6M-31 Fig. air pressure against the top side of the choke valve causes the valve to open slightly against tension of the thermostatic coil. and throttle position. At the same time. It provides the correct air/fuel mixture enrichment to the engine for quick cold engine starting and during the warm-up period. fast idle cam. the fast idle cam follower lever on the end of the primary throttle shaft will drop from the . and a thermostatic coil. 6M-81) The Quadrajet choke valve is located on the primary side of the carburetor. temperature. split choke pick up spring. the offset choke valve. CHOKE SYSTEM (Fig. The thermostatic coil is located in the engine manifold and is connected to the intermediate choke shaft and lever assembly.

3. lbs. The Quadrajet carburetor split choke feature operates during the l a s t . few degrees of choke thermostat rotation. should the engine become loaded or flooded during the starting period. Disconnect fuel inlet line. 7. 4. Remove the two rear carburetor to manifold attaching nuts. As the rod moves to the end of its travel. This keeps the fast idle cam follower lever on the last step of the fast idle cam to maintain fast idle until the engine is thoroughly warm. 6M.95 can be used to disconnect the line. Disconnect carburetor rod. . the end of the choke rod strikes a tang on the air valve lockout lever. The operation of the split choke is controlled by a torsion spring on the intermediate choke lever shaft. it is essential that the carburetor be placed on a holding fixture. The secondary throttle valves in the wide open position extend below the throttle body casting. 4 M V CARBURETOR ASSEMBLY Fig. a tang on the intermediate choke lever contacts the end of the torsion spring. To unload the engine the accelerator pedal should be depressed so that the throttle valves are wide open. 6M-82 4MV Carburetor Assembly REMOVE A N D INSTALL highest step on the fast idle cam to the second step if the throttle is opened. As the thermostatic coil on the engine manifold becomes heated.) and nuts to 14 ft. To install. Remove air cleaner stud. Remove the two front carburetor to manifold attaching bolts (slotted). NOTE: A tool such as MAC S-141 as shown in Fig. A tang on a lever on the choke side of the primary throttle shaft contacts the fast idle cam and through the intermediate choke shaft forces the choke valve slightly open. Without the use of the carburetor stand it is possible to bend or nick the aluminum throttle valves. The choke system is equipped with an unloader mechanism which is designed to partially open the choke valve. When the engine is thoroughly warm. When the choke valve moves toward the open position. it pushes the lockout tang upward and unlocks the air valve. until the coil is hot enough to pull on the intermediate choke lever and overcome the torsion spring tension. The split choke torsion spring has adjustment notches and should always be placed in the specified notch for the application used. Refer to ENGINE Section for idle specifications. 6. 2. It actually works against the thermostatic coil.6M-32 Model 4MV Carburetion normal idle speeds. The purpose is to maintain fast idle speed long enough to keep the engine from stalling but allow the use of a choke coil which lets the choke valve open quickly. 4 M V CARBURETOR DISASSEMBLY NOTE: Before performing any service on this carburetor. the choke coil pulls the intermediate choke lever completely down and allows the fast idle cam to rotate so that the cam follower drops off the last step of the fast idle cam allowing the engine to run at 1. Torque the attaching bolts (6-8 ft. 5. it relaxes its tension and allows the choke valve to open further because of intake air pushing on the off-set choke valve. This gives the engine sufficient fast idle and correct fuel mixture for running until the engine begins to warm up and heat the thermostatic coil. lbs. reverse the removal procedure using a new carburetor to manifold gasket. Choke valve opening continues until the thermostatic coil is completely relaxed at which point the choke valve is wide open. As explained earlier. In the last few degrees of thermostatic coil opening. This allows extra air to enter and lean out the fuel mixture so that the engine will start. air pressure action on the off-set choke valve tends to force the choke valve open against tension of the thermostatic coil. Remove air cleaner. Disconnect vacuum hoses.

(Fig.84) NOTE: Do not bend main well air bleed tubes. (Fig. Remove dashpot from air valve link by rotating bend through hole. air valve shaft and secondary metering rod hanger are calibrated and should not be removed. Fig. pump lever and air valve lever can be removed. Disconnect pump rod from pump lever. 6M-83) (Fig. Tubes are pressed in casting and are not to be removed. 6M-86) 2. (Fig.Model 4MV Carburetion 6M-33 Fig. Remove pump and air horn gasket from around power piston and primary metering rods. 6M-83 Air H orn Attaching Screws Fig. 6M-84) Further disassembly of the air horn is not required for cleaning purposes. 6M-82) 3. 3. (Fig. the choke valve. Remove air horn attaching screws. AIR HORN DISASSEMBLY 1. (Fig. 6M-87). With carburetor on holding fixture. (Fig. Remove secondary metering hanger. remove idle vent valve. 6M. 6M-87) 5. Remove pump return spring and plastic filler. (Fig. 6M-85) NOTE: Air valves. (Fig. 6M-82) 4. 6M-82) 2. 6M-84) rods from 2. Lift air horn straight up. 6M-85 Air Horn Assembly . If part r e placement is required. (Fig. FLOAT BOWL DISASSEMBLY 1. Gasket should r e main on bowl. remove dashpot from air horn by rotating bend through air horn. then. Remove clip from upper end of choke rod and remove choke rod. 6M-84 Air Horn Removed AIR HORN REMOVAL 1. Remove power piston and primary metering rods by pulling straight up on metering rod hanger directly over power piston and remove power piston spring from well (Fig.

6M-88) 5. (Fig. (Fig. (Fig. 6M-90) Fig. 6M-89) 10. 6 M .8 7 Power Piston Assembly 4.8 9 Float Assembly 8. 6M-89) 6. Do not attempt to remove or restake. Remove float retainer and needle assembly. Remove float retaining pin and slide float a s sembly toward front of bowl to disengage needle pull clip. Remove vacuum hose from vacuum break assembly and from tube connection on bowl. (Fig. Remove baffles from secondary side of bowl. 6M-90) 9. If damaged. Remove choke assembly. 6M-89) NOTE: Needle seat is factory staked. then . Remove metering rods from power piston bydisconnecting tension spring from top of each rod then rotating rod to remove from hanger.6M-34 Model 4MV Carburetion Fig. 6M-91) 11.8 6 Pump Assembly Fig. 6 M . (Fig. remove clip and spring from vacuum break link. 6 M . (Fig. Remove pump discharge check ball retainer and check ball. 6M-91) NOTE: If further disassembly of choke is necessary.8 8 M e t e r i n g Rods and Power Piston Assembly Fig. Remove primary metering jets. being careful not to destroy pull clip. replace float bowl assembly. at vacuum break lever. No attempt should be made to remove secondary metering discs. 7. (Fig. 6 M . (Fig.

6M-93) 12. (Fig. 6M-94) and O-ring . 6M-92 Vacuum Break Assembly 14.35 Fig. 6M-94 Hot Idle Compensator remove rod from vacuum break lever. Remove fast idle cam from choke assembly. 6M-90 Primary Metering Jets Fig. 6M-93 Fast Idle Cam Fig. 6M-91 Choke Assembly Fig. (Fig. 6M-93) NOTE: Do not place vacuum break assembly in carburetor cleaner.Model 4MV Carburetion 6M. (Fig. then remove vacuum break assembly from lever. 13. (Fig. 6M-92). Remove lower choke rod and actuating lever from inside of float bowl well. If necessary to replace the choke actuating lever or spring it will be necessary to remove the roll pin. Remove hot idle compensator from float bowl. Spread the retaining ears on bracket next to vacuum break assembly. Fig.

6M-95) filter 1. Remove pump rod. 6M-98 Throttle Body Gasket CLEANING AND INSPECTION NOTE: The carburetor should be cleaned in a cold immersion type cleaner. and spring. of the . gasket. the delrin cam on the air valve shaft will withstand normal cleaning in carburetor cleaner. plastic parts. 6M-96 Throttle Body Attaching Screws 15. Remove throttle body and throttle body to bowl gasket. 6M-95 Fuel Filter Nut Fig. 16. Remove fuel inlet filter nut. (Fig. diaphragms. 3.6M-36 Model 4MV Carburetion Fig. However. pump plungers should not be immersed in carburetor cleaner. Inspect idle mixture needles for damage. 2„ Blow out all passages in castings with compressed air. 6M-96) THROTTLE BODY DISASSEMBLY 1. (Fig. idle mixture screws and springs. (Fig. NOTE: Any rubber parts. Do not pass drills through jets or passages. 6M-97) NOTE: No further disassembly throttle body is required. Fig. 6M-97 Throttle Body Fig. Thoroughly clean carburetor castings and metal parts in an approved carburetor cleaner such as Carbon X (X-55) or its equivalent.

If air valve is damaged. Install throttle body making certain throttle body is properly located over dowels on float bowl. 6M-99 Hot Idle Compensator " O " Ring 1. Replace if necessary with new float needle assembly. then. (Fig. Examine fast idle cam for wear or damage. Install hot idle compensator " O " ring seal in recess in bowl. Examine float needle and diaphragm for wear. 6M-99) NOTE: If vacuum break diaphragm was removed from bracket. air horn assembly must be replaced. Inspect holes in levers for excessive wear or out-of-round conditions. Install fast idle cam on vacuum break assembly. 7. 6M-101 Installing Fast Idle Car . Install spring. 5. 6M-95) 4. FLOAT BOWL 1. Be sure fast idle cam actuating pin on Fig. install throttle body to bowl screws and tighten evenly and securely. 4 M V CARBURETOR ASSEMBLY THROTTLE BODY Fig. Install pump rod in throttle lever by rotating rod. 3. Check all throttle levers and valves for binds or other damage. 6M-97) Back out needles two turns as a preliminary idle adjustment. (Fig. filter. slide vacuum break diaphragm between retaining ears to hold securely. If worn. levers should be replaced. Check air valve for binding conditions. Install fuel inlet filter spring. then. Inspect upper and lower surfaces of carburetor castings for damage. Install vacuum break rod (U-bend end) in diaphragm link with end towards bracket. 2. 6M-100 Vacuum Break Diaphragm Fig. new gasket and inlet nut and tighten nut securely. Install idle mixture needles and springs until seated. (Fig. (Fig. install hot idle compensator. Install new throttle body to bowl gasket over two locating dowels on bowl. install grooved end of rod in hole of actuating lever and retain to vacuum break lever with spring clip. 9. 6M-98) 2. 8. (Fig. 6. 6M-100) 5. 6M-96) Place carburetor on proper holding fixture. then. (Fig.Model 4MV Carburetion 6M-37 4.

Install primary main metering jets. 11. NOTE: Make sure retaining pin is held firmly in place and tang of float is seated on float needle. 6M-103) Install needle retainer and two screws and tighten securely. Install pump lever and retain with roll pin. Insert float needle and diaphragm assembly. Position gasket over two dowels on secondary side of bowl. Install the following. making sure that tension spring is connected to top of each metering rod. Install air horn gasket around primary metering rods and piston. P r e s s down firmly on power piston to insure engagement. Install vacuum hose to tube connection on bowl and vacuum break assembly. AIR HORN 1. Be certain diaphragm is properly positioned before installing retainer. 6M-103 Float Needle and Diaphragm Assembly gauging point 3/16" back from toe). with grooved end pointing inward. Bend f l o a t adjustment. hold float assembly at toe and install retaining pin from pump well side. 17. then holding choke rod. 7. position choke rod actuating lever in well of float bowl and install choke assembly engaging shaft with hole in actuating lever. install pull clip on needle. Remove choke rod from lever for installation later. Install power piston spring in power piston well. 15. if removed. Install pump return spring in pump well. (Fig. (Fig. p r e s s ing downward until seated properly. Refer to ADJUSTMENT Chart for specifications. (Fig. (Fig. up or down for proper 10. a. 6M-102 Installing Primary Metering Jet intermediate choke shaft is located in cut out area of fast idle cam. Using needle nosed pliers to hold needle pull clip. Connect choke rod to choke rod actuating lever (plain end). b. Float Level Adjustment a. 9. measure from top of float bowl gasket surface (gasket removed) to top of float at toe (locate 14. 8. Install plastic filler over float needle. Install float by sliding float lever under pull clip from front to back. Pull clip is properly positioned with open end towards front of bowl. 18. Install retaining screw and tighten securely. .6M-38 Model 4MV Carburetion Fig. 6M-104) Install power piston assembly in well with metering rods properly positioned in metering jets. With float lever in pull clip. 6M-102) (Fig. 6M-101) 6. 13. Be careful not to distort pull clip. reinstall. Install pump discharge check ball and retainer in passage next to pump well. With adjustable T-scale. If primary main metering rods were removed from hanger. Fig. 12. 6M-105) 16. Install pump plunger in pump well.

Place air horn assembly on bowl carefully. 6M-105A) AIR H O R N TO B O W L INSTALLATION positioning secondary metering rods. rods should be positioned with upper ends through hanger holes and towards each other. Care should be taken when installing to be sure dashpot and pump plunger are positioned properly through air horn. With air valve held wide open. 6M-106) 2. Do not force air horn assembly on to float bowl as distortion of secondary metering discs will result.Model 4MV Carburetion 6M-39 Fig. 1. Install dashpot plunger rod through air horn and attach actuating lever to rod. 6M-107) 3. A slight sideward movement will center metering rods in metering discs. Install idle vent actuating rod in pump lever. (Fig. . vent tubes and accelerating well tubes through air horn gasket. (Fig. (Fig. Install choke shaft. c. Install secondary metering rods. 6M-106 Fig. tighten evenly and securely. 6M-104 Power Piston Assembly j «. 6M-105 Installing Plastic Filler Secondary Metering Rods b. ^ P j Fig. 2. Install air horn screws. choke valve and two attaching screws. 6M-105A Metering Rod Installation Fig.

5. measure from top of choke valve wall. Idle Vent Adjustment With the choke valve held in the closed position. to top of pump stem. The dimension between the lower edge of choke valve and air horn. should be as specified on ADJUSTMENT Chart. Measure the distance from the top of choke valve wall. the distance between upper inside edge of air valve and the back of choke valve wall. 6 M . Bend choke rod to adjust. Unloader Adjustment With throttle valves completely closed and pump rod in specified hole of pump lever. the air valve must be locked. should be as specified on ADJUSTMENT Chart.015" to . to top of the pump plunger stem. Choke Rod Adjustment With the fast idle adjustment made and cam follower on second step of fast idle cam and against the high step. Connect choke rod in lower choke lever and retain in upper lever with spring clip. Refer to ADJUSTMENT Chart. Refer to ADJUSTMENT Chart. Adjust the inner arm of the spring tang on the vacuum break bracket so there is . Install idle vent valve. Refer to ADJUSTMENT Chart. Refer to ADJUSTMENT Chart. at torsion spring end. Hold vacuum break diaphragm stem against its seat so vacuum link is at the end of slot. With the vacuum break lever in this position and the choke valve is moved towards open choke to remove looseness in the linkage. Dimension between the lower edge of choke valve. Bend pump lever to adjust. Air V a l v e Lock With air valve wide open and valve against stop tang. With the cam follower positioned against the r i s e to the lowest effective step of the fast idle cam. 6. Position pump rod in inner hole pump lever and retain with spring clip. Bend vacuum link to adjust. at choke lever end. . When the choke valve is moved towards closed position to remove looseness in the linkage. Split Choke Spring Pick-Up After pump rod adjustment has been made. Bend wire tang on pump lever to adjust. open primary throttle to a point where the idle vent just closes. next to vent stack. should be as specified on ADJUSTMENT Chart. rotate the choke valve toward the closed position by pushing down on the vacuum break lever.6M-40 Model 4MV Carburetion Fast Idle Adjustment With primary throttle valves completely closed and the cam follower over the high step of the fast idle cam. open the primary throttle to the wide open position. apply a light force to the vacuum break lever in the direction of closed choke. hold the choke valve toward the closed position using a rubber band on the vacuum break lever.300" clearance between the tang and the front leg of the choke tension spring. Air V a l v e Adjustment With the cam follower on the high step of the fast idle cam. With the valves in this position. by a rubber band on the vacuum break lever. Bend stop tang on dashpot lever to adjust. next to vent stack. 6M-107 Installing Air Horn 4. at choke lever end. Bend the tang on the fast idle lever to adjust. the air valve should be unlocked with a clearance of . turn fast idle screw in three turns after screw makes contact on lever. 4 M V CARBURETOR EXTERNAL ADJUSTMENTS (Fig. open the choke valve to its wide open stop position. Vacuum Break Adjustment Fig.035" between the lockout lever and the front edge of the air valve.1 0 9 ) Pump Rod Adjustment With choke spring pickup located in top notch. the dimension between the lower edge of choke valve and air horn wall should be as specified on ADJUSTMENT Chart. engaging actuating rod and tighten attaching screw.

Model 4MV Carburetion 6M-41 Fig. 6M-103 2GC Carburetor Adjustments .

SPR. UPPER NOTCH SPLIT CH.120" . POS..015 . LOCKOUT CHOKE UPPER NOTCH (R) FAST IDLE SEE "ON CAR ADJ. SPR'. VACUUM BREAK UNLOADER AIR VALVE AUTOMATIC ADJMT. 6M-109 4 M V C a r b u r e t o r Adjustments .300" . V-8" 70262507036250 70262547036254 11/32" 9/32" 3/8" 1-1/8" .300" .035 Fig. ADJ.6M-42 Model 4MV Carburetion USAGE FLOAT LEVEL PUMP ROD IDLE VENT AIR VALVE CHOKE ROD SPLIT CH.170" .

T. in.T. PART NO. and M. A.T. and M. A. in.T. A.T.T. and M. and M.Manual Transmission .T. A.T. Model YF 408OS-3880860 Model BV 7026028 7026027 2GC 7026058 7026059 7036058 7036159 7026052 7026053 7026054 7036052 7036053 4MV 7026254 7036254 7026250 7036250 TAG COLOR ** USAGE 2 5 0 cu. L-6 with K-19 A. with A/C and K-19 3 3 0 cu. and M.T.T.T. . A.F Model 4MV Carburetion 6M-43 CARBURETOR USAGE CHART *CARB.T.T. 2 5 0 cu. and M.T. L-6 A. with K-19 4 2 5 cu. with K-19 Gold Gold Dk. Model 4MV carburetors use a tag with a square hole if equipped with K-19.T. in. A.T. **A.T.T. A. with K-19 A. with A/C A. Blue Gold Silver Gold Silver Orange Purple Lt. in. with K-19 A.T.T. . and M. Tags on K-19 equipped c a r s are square and all others are triangular shaped. A. and M. in.Automatic Transmission M. with A/C and K-19 4 2 5 cu. and M. . Blue Orange Purple Plain Yellow Orange White *Part Number stamped on tag.T.T. M.T.T.T.T. A.T. and M.T. in. with A/C M. 3 3 0 cu.

6M-44 Model 4MV Carburetion .

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